Wiblocks --- ZB1 Assembly Instructions (Rev2)

ZB1 Thru-hole Kit Assembly (Rev1 and Rev2 Boards)

Semiconductors are electrostatic-sensitive devices. Proper ESD handling precautions need to be taken to avoid damage.

Sort Components

Sort the components into the groups shown in the instructions below.
All of the headers supplied with the kit are breakaway headers. The single row headers, J3 (3x1), J5 (6x1), J9 (3x1), J11 (3x1) may come as individual headers or as strips that need to be broken. The double row vertical headers J6 (3x2), J4 (6x2) and J7 (2x2) may come as individual header or as strips that need to be broken.

Assembly Steps

  1. Solder the SMD and thru-hole bottom side components
  2. Solder the power supply circuit components and then test the power supply circuit.
  3. Solder the microcontroller circuit components.
  4. Solder the electro-mechanical components and then test the microcontroller circuitry.
  5. Solder the XBee components.

Bottom Side Components

SMD Components

Three SMD components, F1, C4, C12 are included in the ZB1-KIT2 kit. An easy way to install these SMD components:
  1. Flux both pads of the component footprint.
  2. Reflow solder on one pad of each component footprint.
  3. While holding the SMD component with tweezers slide one of the metalized end into the molten solder.
  4. Solder the other end of the component footprint.
Optional components U3 and C7 are used to provide a 3.3V supply for the XBee using the +5V from J4. See the datasheet for more information

Thru-hole Components

  1. Solder C2, C3
  2. Solder R3, R5
    The tolerance of R3 and R5 is not critical. Some kits include 5% resistors others include 1% resistors. Both types of resistors are pictured to the right. The 5% resistor has four color bands (red, red, brown, gold). The 1% resistor has five color bands (red, red, brown, black, brown).

Top Side Components

Power Supply Circuit

  1. C10, C11
    C10 and C11 are polarized parts. The long lead is the positive. The short lead is the negative. Make sure that the positive lead is inserted into positive hole in the PCB
  2. U4
    Be careful to not mixup U4 and D3. U4 is marked MC33269T-3.3G Make sure that the tab is aligned to the tab marking on the PCB.
  3. D3
    Be careful to not mixup D3 and U4. D3 is marked MBR1545CTG Make sure that the tab is aligned to the tab marking on the PCB.
  4. J9
  5. J10
  6. J8 (optional, not in all kits)
    J8 enables the usage of an external 3.3V power source with the ZB1. If you do not need this function then you can omit the installation of J9.

Testing the Power Supply Circuit

Power the board with a 5V supply through J10. The current drawn from the +5V supply should not exceed a few milliamperes. An easy place to measure the output voltage of U4 is pin one of J9. The voltage should read 3.3V. If there is excessive current or the voltage is accuracy is not within ± 2% quickly shut off the 5V supply and verify the orientation on C10, C11, D3, U4.

Microcontroller Circuit

  1. R1
    The tolerance of R1 is not critical. Some kits include a 5% resistor others include a 1% resistor. Both types of resistors are pictured to the right. The 5% resistor has four color bands (brown, black, orange, gold). The 1% resistor has five color bands (brown, black, black, red, brown).
  2. C6
    In REV3 of the PCB ZB1-KIT2 C6 has been changed to a diode (ZB1 reset circuit change). The board will function properly with C6 but will not be able to be reset by the USB port during program download. Prior to download you will need to press the reset button.
  3. C13, C1
  4. L1
    The value of inductor L1 is not critical. Kits will contain an inductor with a value between 10uH and 15uH. Pictures of a 10uH and a 12uH are shown on the right.
  5. D4
    The negative lead of the LED is the short lead. Align the short lead with the negative marking on the PCB.
  6. R2
    The tolerance of R2 is not critical. Some kits include a 5% resistor others include a 1% resistor. Both types of resistors are pictured to the right. The 5% resistor has four color bands (red, red, brown, gold). The 1% resistor has five color bands (red, red, brown, black, brown).
  7. J3
  8. X1, C5, C9
  9. U1 (socket)
  10. J6
  11. J5
  12. J1
    The J1 that is included with the ZB1 Kit is a right angle connector. If your application requires parallel board mounting or a cable connection then replace J3 with a vertical header. A 2x13 receptacle can also be used.


XBee Components

  1. J4
  2. J7
  3. J11
  4. D1, D2 The negative lead of the LED is the short lead. Align the short lead with the negative marking on the PCB.
  5. XBee Headers (2)
Optional connector J2 is used to connect to DIO-DIO5 of the XBee.








Electromechanical Components

  1. S2
  2. S1, S3
  3. Install the appropriate jumpers (see the datasheet).




Test

Remove the ATmega168 from the antistatic foam and insert it into the U1 socket aligning the notch in the IC package with notch mark indicated on the PCB silkscreen. Be careful to align pins on both sides of the socket prior to pressing the IC into the socket.

The board is now ready to program. See the datasheet for application hints.