Soldering and Assembly of the Siren Kit
These instructions were prepared to simplify the process and fill in some blanks in the instructions provided with the kit
A copy will be provided for use in the lab
Also refer to the diagrams, etc, provided with the kit
n General Comments
ð Carefully identify all pieces in the kit
ð Remove pieces from the paper holder only as you are using them - otherwise there is a good probability of confusing pieces
ð Note that the correct insertion points are labeled on the non copper side of the PC (printed circuit) board
ð Straighten the wire and bend it close to the piece before insertion
ð Insert and solder one piece at a time
ð Refer to color codes. Note that the number of the part and the color code are just below the part.
ð Also note
Ø the parts are not in sequence on the card
Ø yellow may be hard to see
ð Leave solder in the plastic container and withdraw as needed. About 2 inches extending from the tube is enough.
ð Use the wet sponge after each piece is soldered to remove excess
ð Have team members check to ensure the correct piece is being used - before soldering it
ð Accuracy is more important than speed
ð It is easier to solder the leads if you first ensure that they are vertical
ð Do not create solder bridges
n Polarity
ð Capacitor polarity
Ø Electrolytic capacitors have polarity.
The negative lead is marked on the side with a (typically) black band with (typically) a 0 in the band
the negative lead is shorter
the negative lead typically has a slight bend at the end of the lead
note also the the holes on the board are marked + and 1
check again before soldering - get it right!
Ø Disc capacitors do not have polarity
the holes on the board are not marked + and - as are the ones for the electrolytic capacitors
ð LED polarity
Ø The negative lead is shorter
Ø The negative lead is on the side with the flat base
Ø The flat side is also marked on the circuit board - the negative lead goes on the flat side
n PComments Concerning Other Components
ð Integrated Circuit (IC)
Ø Contains many transistors and resistors on a silicon chip
Ø Note alignment marked on the IC and the board
Ø Carefully align the pins with the holes before insertion - if you force them in something will probably break
Ø Insert pins vertically - see above
Ø Be careful with solder - pins are very close together - use only a small amount for each pin
Ø You may need to place a folded piece of paper under the IC to hold it in place while soldering - can also slightly (carefully) bend one of the pins after insertion
ð Variable Resistor (pot)
Ø For volume control
Ø Note the two holes that are not used
ð Transistors
Ø Marked Q1 and Q2 on the board
Ø Note the flat side on the transistor and on the PC board - for proper alignment
Ø Middle pin goes in the back slot
ð Battery leads
Ø Black is negative
Ø Red is positive
Ø Note markings on PC board
ð Jumper wires
Ø Save cutoffs from the above leads
Ø There are two
ð Speaker connection
Ø Cut the brown 12 inch wire into two 6 inch pieces
Ø Remove about 1/4 inch of the insulation from each end
Ø Solder one end of each wire to the speaker and the other end to the PC board
Ø Carefully bend each lug up slightly
Insert the wire so that the exposed part is over the base of the lug
Solder on this end - NOT over the speaker
n Soldering Steps
ð Heat both the lead and the copper before using the solder.
ð Then place a small amount of solder on the tip and let it run into the hole. See where it goes before applying more solder
ð Immediately do the same thing on the other side away from the iron (leave the iron in place)
ð Be sure you are soldering on the correct side
ð Do not move the part until it has cooled
ð Clip excess wire only after the part has cooled
n Safety
ð Team members must wear goggles - this is a generally required safety procedure in the industry and one that I will enforce
ð Observe all other safety procedures that I have covered many times, such as
Ø No playing in the lab
Ø Do not touch or touch anyone else with the hot part of the iron
Ø Do not place face close to the part being soldered
Ø Etc
ð Safety is far more important than speed (and, as explained above, accuracy is also more important than speed)