Data Stream Dissector (DSD) Kit Assembly Instructions last revised 12/31/93 Tools You Will Need ------------------- Soldering iron, pencil type. As some of the chips are CMOS, it is a good idea to use a grounded soldering iron. Use a low wattage iron (15 W) or one with variable temperature control at a low temperature (350 F). Safety glasses Wire cutters, diagonal style Needle-nose pliers Wire strippers Parts and Materials You Will Need That Are NOT In The Kit --------------------------------------------------------- Solder. Use 60/40 Tin/Lead multi-core solder. 0.71 mm diameter worked well for me. Solder wick or de-soldering tool (unless you do flawless work). 75 ohm Coax cable such as RG-59 to go from the circuit card to the panel mounted connectors. About 6 feet total. RG-59 will work but it is difficult to use. RG-179, if you can find it, will be more convenient. Other cable impedances might work, but no guarantees. DC Power Supply. Any voltage between 6 and 18 Volts. About 9 Volts is ideal. Minimum current is 200 mA. Remember: this must be a DC, not an AC power supply. The DSD has an on-board regulator, so an unregulated supply is fine. Select a power supply that has appropriate input specifications for the power system in the country you will use the DSD. Suggested source for 120VAC/60Hz systems such as that in U.S.A.: Radio Shack part number 273-1455. Data Stream Dissector (DSD) Kit Assembly Instructions (page 2 of 7) Parts and Materials That You Might Want To Add ---------------------------------------------- Chassis. For best shielding from electromagnetic interference, use an aluminum or steel box. Printed circuit board standoffs and associated nuts and bolts. For mounting printed circuit board on chassis. Rotary switch and knob for input select. Panel mount LED holders to mount the LEDs on your chassis. Quantity 4. For T 1-3/4 size (5mm diameter LEDs). Suggested Source: Radio Shack part number 276-079. Panel mount switches for C bit selection. Wire to go from the printed circuit board to anything that you decide to panel mount. Header pins and jumpers for jumpers J1 through J9. Documentation You Will Need --------------------------- Parts list (text file). Assembly diagram (Postscript file). Operating instructions (text file). Assembly instructions (this text file). Additional Reference Data ------------------------- Theory Of Operations (text file). Schematic diagram (Postscript file). PAL ABEL source (text file). PAL ABEL documentation (text file). Board layout artwork (Postscript file). Solder mask artwork (Postscript file). Drilling template (Postscript file). PAL JEDEC file (hex text file). Component data sheets (available from the component manufacturers). Data Stream Dissector (DSD) Kit Assembly Instructions (page 3 of 7) Unpacking The Kit ----------------- WARNING: DO NOT UNPACK THE KIT WITHOUT READING THE FOLLOWING ELECTROSTATIC DISCHARGE PRECAUTIONS. Some of the components in the DSD kit can be destroyed by static electricity discharge from your body. If possible, handle all of the components in the kit at an anti-static workstation, with a grounding strap. At the very least, keep one hand touching earth ground while handling the components. Take an inventory of the parts in the kit. Refer to the parts list file for this. The parts list is annotated with information you need to identify the parts. Printed Circuit Board (PCB) Preparation --------------------------------------- If you plan to mount the PCB in a chassis with standoffs, now would be a good time to drill holes in the board. Don't drill through any traces! Stuffing And Soldering Overview ------------------------------- The overall objective is to stuff each component into the printed circuit board and solder it in. Start by getting acquainted with the printed circuit board and the assembly diagram. The diagram is drawn to match the PCB when you are looking at the PCB from the *component* side. The component side is the side without the copper traces on it. The components will be mounted on the component side. The pins or leads of the components will be inserted in the holes in the PCB and protrude out to the *solder* side of the PCB. The leads will be soldered to the pads surrounding the holes on the solder side. The best way to approach stuffing and soldering is to work from one edge of the board to the other. Find a part on the assembly diagram. Refer to the parts list to positively identify the component. And then follow the instructions below to stuff and solder the part. Data Stream Dissector (DSD) Kit Assembly Instructions (page 4 of 7) Component Orientation --------------------- Determine which way to insert the component. Integrated circuits tend to have some sort of a dimple, depression, or semi-circle cut out of one end. Hold the IC so that dimple is at the left. Now you should be able to read the writing on the IC (meaning, the writing is not upside-down. Pin 1 on the IC is at the lower left. The PCB has a rectangular (instead of oval) pad for pin 1 on each IC. This is also illustrated on the assembly diagram. Resistors, inductors, and ceramic, polypropylene, and polyester capacitors have no polarity. You can insert them any way you like. The LEDs in the kit have one long lead and one short lead. The long lead is the anode. The short lead is the cathode. If you look at the PCB, there is a little diode symbol drawn in copper trace next to each LED position. The symbol is a triangle with a line across the apex. The anode goes to the hole nearest the base of the triangle. The cathode goes to the hole nearest the line across the apex of the triangle. Electrolytic capacitors are polarized and will explode if you don't put them in the right way. The assembly diagram shows where the + and - leads go. Most electolytics mark the - lead. The + lead is the other lead. The DIP-switch has a pin 1 just like an IC. If you can read the switch legends, then pin 1 is at the lower left. The Toslink fiber optic connectors will only fit one way. The transformers will fit two different ways but it does not matter which way. Proper orientation for the transistors is illustrated in the assembly diagram. Component Insertion ------------------- Usually you need to bend the leads in a bit on the ICs to insert them. Carefully roll the IC on a table top so that all of the leads on one side bend in a bit. Then do the other side. You should not crease the leads. Discrete (2 or 3 terminal) components might need to have their leads bent to fit the PCB layout. Do this with pliers. In general, components should sit on the board, not above it. Note: If you plan to use panel-mounted switches or LEDs, do not mount those components on the board. Data Stream Dissector (DSD) Kit Assembly Instructions (page 5 of 7) Soldering --------- WARNING: ALWAYS WEAR EYE PROTECTION WHEN SOLDERING!!! Although soldering is easy, there is no way I can teach you to do it in this text file. If you have never done it before, get someone to show you how. Here are a few reminders: Practice on a resistor before you attempt an IC. Touch the soldering iron to the connection for the briefest time possible. Use as little solder as possible. The solder should flow all around the connection. Solder connections should be smooth and shiny. Be especially careful with the CS8412 IC. It is expensive! Clip Leads and Install Jumpers ------------------------------ Clip all leads to about the same length as the IC leads. The pieces of wire will come in handy for installing the jumpers, described below. WEAR EYE PROTECTION WHEN CLIPPING LEADS. There are two types of jumpers on the board. The first type are numbered J1-J9 on the assembly diagram. We put these in because they are the gateway to future circuitry you might decide to add. They link the digital audio receiver to the transmitter. For example, some day you might insert a DSP between there. These 9 signals are appropriate for connecting to additional circuitry in the same chassis, but not suitable for sending to a separate box. For now, you can insert wire for these jumpers or you can install header pins and place removable jumpers over those header pins. The other kind of jumper is drawn on the assembly diagram but not labeled or numbered. These are necessary because we went with a low-cost single-sided PCB. There was no other way to route all the signals around the board. Use wire for these jumpers. The wire does not need to be insulated. There are 17 of these jumpers, including the easy-to-miss ones under C2 and to the right of U4. Data Stream Dissector (DSD) Kit Assembly Instructions (page 6 of 7) Finishing Up ------------ Now you should have the entire board stuffed and soldered. All jumpers have been installed. You have checked everything twice. This probably took about 2 hours so far. Note: there will be some unused holes on the PCB. Wire the RCA jacks to the PCB using 75 ohm coax cable. One jack gets wired to each location marked "IEC958 In", "Direct In", or "IEC958 Out" on the assembly diagram. The diagram shows one line with a circle around it. That center conductor of the coax goes to that hole. The shield on the coax cable goes to the other hole. The center conductor goes to the long terminal on the RCA jack. The shield on the coax cable goes to the short terminal on the RCA jack. IMPORTANT: WHEN MOUNTING RCA CONNECTORS, DO NOT CONNECT THE RING OR SHIELD TO COMMON. The DSD design uses fully isolated inputs and outputs. That's what the transformers are for. Both the pin and the ring of the RCA jack get wired to the board. Neither gets wired to the chassis or to ground or to V- or to anything else but the correct hole on the PCB. Make sure the connector does not touch the chassis. Wire up any panel mounted components you chose to install. Wire the DC power supply to the + and - locations on the PCB. WARNING: DO NOT INVERT THE POLARITY ON THE DC INPUT. Use a voltmeter to check the polarity of the DC power supply. Clean all debris off of the board. Check the board for solder bridges, cold solder joints, missing solder joints. Recheck component placement and orientation. Check the orientation of the electrolytic capacitors and the power supply one more time! Data Stream Dissector (DSD) Kit Assembly Instructions (page 7 of 7) Testing ------- Find a good place to connect a voltmeter to the Vcc and GND busses of the PCB. GND is the same as the "-" power input. But Vcc is different from the "+" power input because it is regulated. Vcc is at the "+" pin of the 10uF capacitor. Apply DC power to the board. Immediately check to see that the voltage from Vcc to GND is between 4.5V and 5.5V. If not, DISCONNECT THE POWER SUPPLY QUICK!!! If your voltage is good, wait 30 seconds and feel the tops of the ICs. None should be too hot to touch. If they are, then power down - you have big problems. You should not see any smoke or flame. The board might smell just slightly at first, but if it stinks, then something burned up. Refer to the operating instructions to completely test your DSD. Good luck!