CirKits.com DAS1-c1 Dark Activated Switch Assembly Instructions Instructions Rev: March 6, 2012 Check http://www.cirkits.com/das1 for update information. General Hints and Tips: -Parts go on the side of the board with white lettering (silkscreen). -Do not overheat the semiconductors when soldering, especially the LEDs. -Use a clip-on heat sink on semiconductor leads during soldering. -Only use electronic grade 60/40 rosin core solder or equivalent. -Acid core solder destroys electronic parts, don't use it. -A proper solder connection is shiny, smooth, and concave shaped. -Look at the photograph of an assembled DAS1 circuit board on http://www.cirkits.com/das1/ for reference. -When working with long leaded parts, insert the leads into the board holes, bend the leads so that the part fits snugly to the board, solder the leads, then clip off the excess wire. Tools and materials for Construction and Alignment: Electronic grade Soldering Iron 60/40 rosin core solder Needle nose pliers Diagonal wire cutters #1 Phillips head screw driver Fine gauge flat screw driver for circuit adjustment volt meter Rubbing Alcohol and a tooth brush (recommended) 0-20 VDC variable power supply Follow and check all of the [] boxes as you proceed. Solder the resistors to the board. If you are unsure about the resistor color codes, verify the part values with an ohm-meter. [] Solder one 270 ohm (red violet brown) resistor at R1. [] Solder one 330 ohm (orange orange brown) resistor at R3. [] Solder three 1K (brown black red) resistors at R10,R16,R17. [] Solder one 4.7K (yellow violet red) resistor at R4. [] Solder three 10K (brown black orange) resistors:R2,R5,R9. [] Solder seven 100K (brown black yellow) resistors:R6,R7,R8,R12,R13, R14,R15. [] Solder one 1M (brown black green) resistor at R11. [] Solder the 470uF capacitor to the board at C4. The long lead on the capacitor goes in the hole with the + sign, the white - stripe on the capacitor is closer to the center of the board. [] Solder five 100nF capacitors (marked 104 or 0.1uF) to the board at C1,C2,C3,C5, and C6. [] Install the large 6A05 diode at D1, the white band should go toward the edge of the board. Bend the leads over the silvered area on the bottom of the board and solder. [] Solder the two 1N5818 Schottky diodes at D2 and D3. The white bands on the diodes should line up with the circuit board markings. [] Solder VR1, the 78L08 regulator, to the board. Align the flat side of the regulator with the board marking. [] Solder Q3, the 2N3906 transistor, to the board. Align the flat side of the transistor with the board marking. [] Solder Q2 and Q4, the 2N3904 transistors, to the board. Align the flat side of the transistors with the board marking. [] Bend the leads of Q1, the IRF4905 MOSFET, so that the part fits into the board and the mounting hole lines up with the circuit board hole. [] Use the toothpick and apply a thin layer of heat sink grease from the plastic capsule to the back side of Q1. Install Q1 on the board using the 4-40 screw, lock washer, and nut. Bend the Q1 leads over the silvered areas on the bottom of the board, then solder the leads. [] Insert the fuse into the two fuse clips and solder the fuse assembly to the board at the location marked F1. The flat side of the clips go toward connector CN1. [] Solder the SPDT center-off switch, S1 to the board. [] Solder RV1, the 200K potentiometer (marked W204), to the board. The adjustment screw is oriented near the board edge. [] Solder RV2, the 1M potentiometer (marked W105), to the board. The adjustment screw is oriented near the board edge. [] Solder IC1, the TLC2722 dual R2R op-amp to the board, pin 1 on the IC may be marked with a small circle indentation. Pin 1 goes near R13. [] Install the 4 pin connector, CN1 on the board. Solder the connector pins to the board. [] Install the 2 pin connector to the board position marked CDS so that the holes are facing the outside edge of the board. Solder the connector pins to the board. [] Bend the leads of LED1 and LED2 so that the parts fit into the board holes and the LEDs hang over the side of the board pointing sideways, the flat side of the LEDs must be aligned with the board markings. The LEDs may also be mounted pointing up, side pointed LEDs can protrude if the board is mounted in a box. [] Insert the CDs cell into the CDS connector, gently tighten the connector's screws to hold the cell. If the CDs cell is to be mounted remote from the board (recommended), solder the CDs cell to a twisted pair wire and connect the other end of the wires to the CDS connector. The CDs / twisted pair solder joint should be covered with insulating electrical tape and secured with a plastic wire tie or a metal clamp. [] Verify that C4, the LEDs, the IC, diodes, and transistors are oriented correctly with the white markings on the circuit board. [] Check all of the solder joints, retouch any cold solder joints. The board assembly should now be complete. [] Clean the leftover solder flux from the bottom of the circuit board with rubbing alcohol. Use an old tooth brush to scrub the board then soak up the residue with a tissue. Repeat until the board is clean.