HARDWARE ASSEMBLY MANUALP13361: System Dynamics Filtering Laboratory

Release Date: January 25, 2013 Revision: -

PURPOSE

The purpose of this document is to outline the procedures to be used in order to properly assemble the printed circuit board (PCB) and hardware module portion of the System Dynamics Filtering Laboratory.

TABLE OF CONTENTS

PURPOSE................................................................................................................................................................... 1

TABLE OF CONTENTS................................................................................................................................................. 1

ENGINEERING SPECIFICATIONS, REV B....................................................................................................................... 1

MASTER LIST OF TEST EQUIPMENT............................................................................................................................. 2

TESTS........................................................................................................................................................................ 3

TEST 1: PERFORM ACTIVITY..................................................................................................................................................3

TEST 2: DESIGN POSSIBILITY/OUTCOME..................................................................................................................................5

TEST 3: STORAGE SIZE.........................................................................................................................................................7

TEST 4: MINOR MAINTENANCE.............................................................................................................................................8

TEST 5: MAJOR REPAIR......................................................................................................................................................10

TEST 6: AUDIO LEVEL.........................................................................................................................................................12

APPENDIX................................................................................................................................................................ 13

TABLE OF FIGURES

No table of figures entries found.

Hardware Assembly Manual P13361

MASTER LIST OF PRODUCT COMPONENTS

The following is a master list of product components used to assemble the printed circuit board (PCB) and hardware module. See the Bill of Materials for more information.

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P/N ID Qty Part Name Description

A3B 1 FILTER PCB ASSY Printed circuit board with all attached componenets

A301 1 BREADBOARD

A302 16 STAND_OFF PCB stand off, 1.5" long, 4-40 threaded, aluminum

A303 1 FILTER_MODULE_ENCLOSURE

A305 1 MOUNTING_PLATE

A306 30 STAND_OFF_SCREW Screws for standoffs 4-40 X 1/2"

A307 4 MOUNTING_PLATE_SCREW

A308 2 IC_LM741_AUDIO_AMPLIFIER

A3A01 1 JACK_BANANA_F_WHT

A3A02 1 JACK_BANANA_F_YLW

A3A03 2 JACK_BANANA_F_BLK

A3A04 2 JACK_BANANA_F_RED

A3A05 1 HEADPHONES

A3A06 2 ADAPTER_BANANA_M_BNC_F

A3A07 1 CNCTR_BANANA_MM_WHT

A3A08 1 CNCTR_BANANA_MM_YLW

A3A09 1 CNCTR_LINE_IN_3.5mm

A3A10 1 CNCTR_BREADBOARD_PWR

A3A11 1 CNCTR_BREADBOARD_GND

A3A12 1 CNCTR_BREADBOARD_OUT

A3A13 2 JACK_3.5mm_FEMALE Female mono headphone jack, 3.5mm,

A3A14 1 INTERFACE_PANEL

A3A15 1 RUBBER_SUPPORT

A3A17 1 VOICE_REC_BOARD

A3B01 1 PCB_BLANK

A3B02 4 CAPACITOR_1uF CAP ALUM 1UF 50V 20% RADIAL

Breadboard, 1 terminal strip, 2 bus strips, 270 contacts, 3.3" x 1.8", screw fastened

Filter module activitiy enclosure, ABS plastic, hinged lid with padlock option, 7.87"X5.9"X3.93"Plexi-glass plate used to mount hardware in enclosure

Screws for mounting plate to enclosure fastening 8-32 X 1/2"Integrated Circuit LM741 through hole, 8 pin, audio amplifier, used in breadboardFemale banana jack, surface mount, white (for reference PS connection)Female banana jack, surface mount, yellow (for +9V PS connection)Female banana jack, surface mount, black (for Ground)Female banana jack, surface mount, red (for FCN/DAQ connection)Headphones to be included with hardware, connect to line out jackAdapter male pos/gnd banana to male BNC (oscilloscope)Male banana to male banana patch cord, 24", white (for ground PS connection)Male banana to male banana patch cord, 24", yellow (for +9V PS connection)Mono 2' 3.5mm phone plugs (male-male), for connection between audio player and line in/mic jackPower / voltage in connection to breadboard from PCB, red, 22AWG, 100' (<1' needed)Ground connection to breadboard from PCB, black, 22AWG, 100' (<1' needed)Output voltage connection to PCB from breadboard, green 22AWG, 100' (<1' needed)

Plexi-glass plate used for input/output jack support, 4"X1.7"X.125" used, comes in 6"X12"Rubber sheet squares used to support Voice Recording Board, comes in 1/2" X 1/8" X 36" barsSeparated PCB that contains the voice recorder circuit and various attachmentsPrinted circuit board (no attached components), 4" x 3.3"X0.062", 13.2 sq. inches

C1, C2, C3, C4

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A3B04 3 CAPACITOR_100uF

A3B05 1 CAPACITOR_47nF

A3B06 3 CAPACITOR_100nF

A3B07 1 CAPACITOR_220uF

A3B08 4 DIODE_GP 1N4001 diode, general purpose

A3B09 1 LED_6.35mm_RED

A3B10 1 CONNECTION_HEADER Connector to PCB, JP1 JP2 filter select/out selectA3B11 1 RESISTOR_1kOHM Resistor, through hole, 1% tol., (1 kilo-Ohm)A3B13 R1, R6 2 RESISTOR_100 OHM Resistor, through hole, 5% tol., (100 Ohm)A3B14 1 RESISTOR_330 OHM Resistor, through hole, 5% tol., (330 Ohm)A3B15 2 RESISTOR_1.6kOHM Resistor, through hole, 5% tol., (1.6K -Ohm)A3B16 1 RESISTOR_ 3.16kOHM Resistor, through hole, 1% tol., ( 3.16K -Ohm)A3B17 1 RESISTOR_ 800OHM Resistor, through hole, 5% tol., (800-Ohm)A3B18 1 SWITCH_SPDT_SLIDER SPDT slider switch, surface mount

A3B20 1 IC_LM7805_VOLTAGE_REGULATOR

A3B21 2 TP_BLUE Test point, blueA3B22 2 TP_RED Test point, redA3B21 2 TP_BLACK Test point, blackA3B22 4 JUMPER Connecting Jumpers for A3B10

C5, C6, C7

Ceramic capacitor, through hole, 20% tol., (100micro-Farrad)Ceramic capacitor, through hole, 20% tol., (47 nano-Farrad)Ceramic capacitor, through hole, 5% tol., (100 nano-Farrad)Ceramic capacitor, through hole, 5% tol., (220 micro-Farrad)

Red LED panel indicator light, through hole, 635nm, 1.8V

Integrated Circuit, LM7805, through hole, 3 pin, voltage regulator

MASTER LIST OF ASSEMBLY EQUIPMENT

The following is a master list of equipment used to assemble the printed circuit board (PCB) and hardware module.

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ID Qty Description Suggested Model1 1 Electronics laboratory studio classroom System Dynamics classroom (GLE-2120)

2 1 DC 12V Power Supply GW Instek Laboratory DC Power Supply (GPS-3303)

3 1 Oscilloscope

4 1 Any Electronics laboratory computer

5 2 BNC Female-Female Patch Cable Pamona 48" BNC F-F Patch Cable (4277-C-48)6 1 Soldering Iron Pace 120V PS-90 Soldering Iron (8007-0528)7 1 Lead Free Solder Multicore 28 Gauge Solder (796065)8 1 Needle Nose Pliers Stanley 5" Needle Nose Pliers (84-096)

9 1 Wire Cutters Craftsman Wire Cutter-Stripper and Crimper (76575)

10 1 Wire Strippers / Crimpers Craftsman Wire Cutter-Stripper and Crimper (76575)

11 1 Hex Screwdriver Craftsman 6-in-1 LED Screwdriver (35722)12 1 Slotted Screwdriver Craftsman 6-in-1 LED Screwdriver (35722)13 1 CA Glue Super Glue 2g (15109)

14 1 1/4" Rachet

15 1 7/16" Scocket

16 1 3/32" Socket

17 1 Utility Knife Craftsman Twin Blade Lockback Knife (#95013)

Agilent Technologies 60MHz Digital Storage Oscilloscope (DSO3062S)

Computer w/ Matlab, Labview, and attached DAQ

Craftsman 1/4 in Drive Quick Release Teardrop Rachet (#44807)Craftsman 9 pc. Universal 1/4 in Dr. Socket Set, Inch (#38209)Craftsman 9 pc. Universal 1/4 in Dr. Socket Set, Inch (#38209)

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PRINTED CIRCUIT BOARD (PCB) ASSEMBLY

This section outlines how to assemble the custom printed circuit board (PCB).

PRODUCT COMPONENTS

P/N ID Qty Part Name Description

A3B01 1 PCB_BLANK

A3B02 4 CAPACITOR_1uF CAP ALUM 1UF 50V 20% RADIAL

A3B04 3 CAPACITOR_100uF

A3B05 1 CAPACITOR_47nF

A3B06 3 CAPACITOR_100nF

A3B07 1 CAPACITOR_220uF

A3B08 4 DIODE_GP 1N4001 diode, general purpose

A3B09 1 LED_6.35mm_RED

A3B10 1 CONNECTION_HEADER Connector to PCB, JP1 JP2 filter select/out selectA3B11 1 RESISTOR_1kOHM Resistor, through hole, 1% tol., (1 kilo-Ohm)A3B13 R1, R6 2 RESISTOR_100 OHM Resistor, through hole, 5% tol., (100 Ohm)A3B14 1 RESISTOR_330 OHM Resistor, through hole, 5% tol., (330 Ohm)A3B15 2 RESISTOR_1.6kOHM Resistor, through hole, 5% tol., (1.6K -Ohm)A3B16 1 RESISTOR_ 3.16kOHM Resistor, through hole, 1% tol., ( 3.16K -Ohm)A3B17 1 RESISTOR_ 800OHM Resistor, through hole, 5% tol., (800-Ohm)A3B18 1 SWITCH_SPDT_SLIDER SPDT slider switch, surface mount

A3B20 1 IC_LM7805_VOLTAGE_REGULATOR

A3B21 2 TP_BLUE Test point, blueA3B22 2 TP_RED Test point, redA3B21 2 TP_BLACK Test point, blackA3B22 4 JUMPER Connecting Jumpers for A3B10

Printed circuit board (no attached components), 4" x 3.3"X0.062", 13.2 sq. inches

C1, C2, C3, C4C5, C6, C7

Ceramic capacitor, through hole, 20% tol., (100micro-Farrad)Ceramic capacitor, through hole, 20% tol., (47 nano-Farrad)Ceramic capacitor, through hole, 5% tol., (100 nano-Farrad)Ceramic capacitor, through hole, 5% tol., (220 micro-Farrad)

Red LED panel indicator light, through hole, 635nm, 1.8V

Integrated Circuit, LM7805, through hole, 3 pin, voltage regulator

ASSEMBLY EQUIPMENT

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# Qty Description Suggested Model1 1 Electronics laboratory studio classroom System Dynamics classroom (GLE-2120)

2 1 DC 12V Power Supply GW Instek Laboratory DC Power Supply (GPS-3303)

3 1 Oscilloscope

4 2 BNC Female-Female Patch Cable Pamona 48" BNC F-F Patch Cable (4277-C-48)5 1 Soldering Iron Pace 120V PS-90 Soldering Iron (8007-0528)6 1 Lead Free Solder Multicore 28 Gauge Solder (796065)7 1 Needle Nose Pliers Stanley 5" Needle Nose Pliers (84-096)8 1 Hex Screwdriver Craftsman 6-in-1 LED Screwdriver (35722)

Agilent Technologies 60MHz Digital Storage Oscilloscope (DSO3062S)

PROCEDURE

1. Here there will be the assembly procedure for the PCB with appropriate pictures

OPERATION TESTING

1. Board testing procedure that tells how to make sure the board works properly

DEBUGGING NOTES

Any debug notes about testing here

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HARDWARE MODULE ASSEMBLY

This section outlines how to assemble the hardware module.

PRODUCT COMPONENTS

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P/N ID Qty Part Name Description

A3B 1 FILTER PCB ASSY Printed circuit board with all attached componenets

A301 1 BREADBOARD

A302 15 STAND_OFF PCB stand off, 1.5" long, 4-40 threaded, aluminum

A303 1 FILTER_MODULE_ENCLOSURE

A305 1 MOUNTING_PLATE

A306 30 STAND_OFF_SCREW Screws for standoffs 4-40 X 1/2"

A307 4 MOUNTING_PLATE_SCREW

A308 2 IC_LM741_AUDIO_AMPLIFIER

A3A01 1 JACK_BANANA_F_WHT

A3A02 1 JACK_BANANA_F_YLW

A3A03 2 JACK_BANANA_F_BLK

A3A04 2 JACK_BANANA_F_RED

A3A05 1 HEADPHONES

A3A06 2 ADAPTER_BANANA_M_BNC_F

A3A07 1 CNCTR_BANANA_MM_WHT

A3A08 1 CNCTR_BANANA_MM_YLW

A3A09 1 CNCTR_LINE_IN_3.5mm

A3A10 1 CNCTR_BREADBOARD_PWR

A3A11 1 CNCTR_BREADBOARD_GND

A3A12 1 CNCTR_BREADBOARD_OUT

A3A13 2 JACK_3.5mm_FEMALE Female mono headphone jack, 3.5mm,

A3A14 1 INTERFACE_PANEL

A3A15 1 RUBBER_SUPPORT

A3A17 1 VOICE_REC_BOARD

Breadboard, 1 terminal strip, 2 bus strips, 270 contacts, 3.3" x 1.8", screw fastened

Filter module activitiy enclosure, ABS plastic, hinged lid with padlock option, 7.87"X5.9"X3.93"Plexi-glass plate used to mount hardware in enclosure

Screws for mounting plate to enclosure fastening 8-32 X 1/2"Integrated Circuit LM741 through hole, 8 pin, audio amplifier, used also for built in active filtersFemale banana jack, surface mount, white (for reference PS connection)Female banana jack, surface mount, yellow (for +9V PS connection)Female banana jack, surface mount, black (for Ground)Female banana jack, surface mount, red (for FCN/DAQ connection)Headphones to be included with hardware, connect to line out jackAdapter male pos/gnd banana to male BNC (oscilloscope)Male banana to male banana patch cord, 24", white (for ground PS connection)Male banana to male banana patch cord, 24", yellow (for +9V PS connection)Mono 2' 3.5mm phone plugs (male-male), for connection between audio player and line in/mic jackPower / voltage in connection to breadboard from PCB, red, 22AWG, 100' (<1' needed)Ground connection to breadboard from PCB, black, 22AWG, 100' (<1' needed)Output voltage connection to PCB from breadboard, green 22AWG, 100' (<1' needed)

Plexi-glass plate used for input/output jack support, 4"X1.7"X.125" used, comes in 6"X12"Rubber sheet squares used to support Voice Recording Board, comes in 1/2" X 1/8" X 36" barsSeparated PCB that contains the voice recorder circuit and various attachments

ASSEMBLY EQUIPMENT

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# Qty Description Suggested Model1 1 Electronics laboratory studio classroom System Dynamics classroom (GLE-2120)

2 1 DC 12V Power Supply GW Instek Laboratory DC Power Supply (GPS-3303)

3 1 Oscilloscope

5 2 BNC Female-Female Patch Cable Pamona 48" BNC F-F Patch Cable (4277-C-48)6 1 Soldering Iron Pace 120V PS-90 Soldering Iron (8007-0528)7 1 Lead Free Solder Multicore 28 Gauge Solder (796065)8 1 Needle Nose Pliers Stanley 5" Needle Nose Pliers (84-096)

9 1 Wire Cutters Craftsman Wire Cutter-Stripper and Crimper (76575)

10 1 Wire Strippers / Crimpers Craftsman Wire Cutter-Stripper and Crimper (76575)

11 1 Hex Screwdriver Craftsman 6-in-1 LED Screwdriver (35722)12 1 Slotted Screwdriver Craftsman 6-in-1 LED Screwdriver (35722)13 1 CA Glue Super Glue 2g (15109)

14 1 1/4" Rachet

15 1 7/16" Scocket

16 1 3/32" Socket

17 1 Utility Knife Craftsman Twin Blade Lockback Knife (#95013)

Agilent Technologies 60MHz Digital Storage Oscilloscope (DSO3062S)

Craftsman 1/4 in Drive Quick Release Teardrop Rachet (#44807)Craftsman 9 pc. Universal 1/4 in Dr. Socket Set, Inch (#38209)Craftsman 9 pc. Universal 1/4 in Dr. Socket Set, Inch (#38209)

PROCEDURE

INTERFACE PANEL

1. Use the utility blade (ID 16) to cut sections of rubber (A3A15) to cover the bottom of the voice recorder board (A3A17)

2. Once the rubber is cut, use the CA glue (ID 13) to glue it to the voice recorder board (See Figure 1)

Figure 1: Rubber Backing on Voice Recorder Board

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3.

4. Per Figure 2 below, thread the yellow (A3A02), white (A3A01), red x 2 (A3A04), and black x 2 (A3A03) banana jacks, and the mono audio jacks (A3A13) into the blank interface panel (A3A14)

Figure 2: Jack Locations on Interface Panel

5. Use the ¼” rachet (ID 13) and the 7⁄16” socket (ID 14) to tighten down the banana jacks

6. Use the ¼” rachet (ID 13) and the 3⁄32” socket (ID 15) to tighten down the audio jacks

7.

OPERATION TESTING

8. Board testing procedure that tells how to make sure the board works properly

DEBUGGING NOTES

Any debug notes about testing here

9.

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APPENDIX

ACTIVITY UNDERSTANDING QUIZ............................................................................................................................. 14

TEST DATA SHEETS................................................................................................................................................... 16

TEST 1: PERFORM ACTIVITY................................................................................................................................................16

TEST 2: DESIGN POSSIBILITY/OUTCOME................................................................................................................................17

TEST 3: STORAGE SIZE.......................................................................................................................................................19

TEST 4: MINOR MAINTENANCE...........................................................................................................................................20

TEST 5: MAJOR REPAIR......................................................................................................................................................21

TEST 6: AUDIO LEVEL.........................................................................................................................................................22

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ACTIVITY UNDERSTANDING QUIZ

Name:_________________________ Date: ____/____/2013Grade: ⁄ 10

1.) Questions to be determined by the content of the laboratory activity manual. The questions are likely to span more than one line.a. Answer 1b. Answer 2c. Answer 3d. Answer 4e. Answer 5

2.) Questions to be determined by the content of the laboratory activity manual. The questions are likely to span more than one line.a. Answer 1b. Answer 2c. Answer 3d. Answer 4e. Answer 5

3.) Questions to be determined by the content of the laboratory activity manual. The questions are likely to span more than one line.a. Answer 1b. Answer 2c. Answer 3d. Answer 4e. Answer 5

4.) Questions to be determined by the content of the laboratory activity manual. The questions are likely to span more than one line.a. Answer 1b. Answer 2c. Answer 3d. Answer 4e. Answer 5

5.) Questions to be determined by the content of the laboratory activity manual. The questions are likely to span more than one line.a. Answer 1b. Answer 2c. Answer 3

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d. Answer 4e. Answer 5

6.) Questions to be determined by the content of the laboratory activity manual. The questions are likely to span more than one line.a. Answer 1b. Answer 2c. Answer 3d. Answer 4e. Answer 5

7.) Questions to be determined by the content of the laboratory activity manual. The questions are likely to span more than one line.a. Answer 1b. Answer 2c. Answer 3d. Answer 4e. Answer 5

8.) Questions to be determined by the content of the laboratory activity manual. The questions are likely to span more than one line.a. Answer 1b. Answer 2c. Answer 3d. Answer 4e. Answer 5

9.) Questions to be determined by the content of the laboratory activity manual. The questions are likely to span more than one line.a. Answer 1b. Answer 2c. Answer 3d. Answer 4e. Answer 5

10.) Questions to be determined by the content of the laboratory activity manual. The questions are likely to span more than one line.a. Answer 1b. Answer 2c. Answer 3

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d. Answer 4e. Answer 5

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TEST DATA SHEETTest 1: Perform Activity

Supervising Engineer: ____________________________________________________

Date Performed: ________________________________________________________

Test Equipment Checklist:

# Qty Description Acquired? Utilized Model

1 1 Electronics laboratory studio classroom

2 1 DC 12V Power Supply

3 1 Oscilloscope

4 1 Computer w/ Matlab, Labview, and attached DAQ

5 2 BNC Female-Female Patch Cable

6 2 Stopwatch

7 1 System Dynamics Instructor

8 2 ME Student

9 1 Activity Understanding Quiz

Test Documentation:

Student Laboratory Time Hands-On TimeHands-On Percentage % = (H.O. Time /

Total Time)

Test Notes:

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Pass / Fail? _________________________________________________________________

Engineer Signature: ____________________________________ Date: ______________

TEST DATA SHEETTest 2: Design Possibility/Outcome

Supervising Engineer: ____________________________________________________

Date Performed: ________________________________________________________

Test Equipment Checklist:

# Qty Description Acquired? Utilized Model

1 1 Electronics laboratory studio classroom

2 1 DC 12V Power Supply

3 1 Oscilloscope

4 1 Computer w/ Matlab, Labview, and attached DAQ

5 2 BNC Female-Female Patch Cable

Test Documentation:

See following page

Test Notes:

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Pass / Fail? _________________________________________________________________

Engineer Signature: ____________________________________ Date: ______________

Test Documentation:

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# #

1 6

2 7

3 8

4 9

5 10

Implementation Method

(H/W or S/W)Filter Description / Wiring Schematic (include

component details)Implementation Method

(H/W or S/W)Filter Description / Wiring Schematic (include

component details)

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TEST DATA SHEETTest 3: Storage Size

Supervising Engineer: ____________________________________________________

Date Performed: ________________________________________________________

Test Equipment Checklist:

# Qty Description Acquired? Utilized Model

1 1 Tape Measure

Test Documentation:

Hardware Kit DimensionsLegnth Width Height

Test Notes:

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Pass / Fail? _________________________________________________________________

Engineer Signature: ____________________________________ Date: ______________

TEST DATA SHEETTest 4: Minor Maintenance

Supervising Engineer: ____________________________________________________

Date Performed: ________________________________________________________

Test Equipment Checklist:

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# Qty Description Acquired? Utilized Model

1 2 Stopwatch

2 1 Soldering Iron

3 1 Lead Free Solder

4 1 Needle Nose Pliers

5 1 Wire Cutters

6 1 Wire Strippers / Crimpers

7 1 Phillips Screwdriver

8 1 Slotted Screwdriver

9 1 Replacement Jumper Wire

Test Documentation:

Repair Time

Test Notes:

Pass / Fail? _________________________________________________________________

Engineer Signature: ____________________________________ Date: ______________

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Test 5: Major Repair

Supervising Engineer: ____________________________________________________

Date Performed: ________________________________________________________

Test Equipment Checklist:

# Qty Description Acquired? Utilized Model

1 2 Stopwatch

2 1 Phillips Screwdriver

3 1 Soldering Iron

4 1 Lead Free Solder

5 1 Slotted Screwdriver

6 1 Replacement Assembled PCB

Test Documentation:

PCB Assembly Time Replacement Time

Test Notes:

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Pass / Fail? _________________________________________________________________

Engineer Signature: ____________________________________ Date: ______________

TEST DATA SHEETTest 6: Audio Level

Supervising Engineer: ____________________________________________________

Date Performed: ________________________________________________________

Test Equipment Checklist:

# Qty Description Acquired? Utilized Model

1 1 Electronics laboratory studio classroom

2 1 DC 12V Power Supply

3 1 Tape Measure

4 6 Speaker

5 1 Decibel Meter

Test Documentation:

Trial Decibel Rating

1

2

3

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Test Notes:

Pass / Fail? _________________________________________________________________

Engineer Signature: ____________________________________ Date: ______________

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