* Construction of the peripheral extension options kit

1. Outline

2. Purchase

3. Tools for assembly

4. Construction

5. View of completed board

6. Operation check

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Updated May 30, 2005 18:37

* Outline

Characteristics / Specifications / Circuit diagram / Connector pin layout / List of components

5.1.1 Characteristics

This kit is required for completing the SUGSI IT Exercises work and operation checks.

The kit will be used by connecting it to the external connection connector of the PICNIC kit. Two I/O connections via a photoisolator IC as well as two analog inputs are available on the terminal board. In particular, the digital output is an output connection based on a mechanical relay and does not choose the connecting device. With induction loads, connection capacities of 5A (120VAC) can be controlled. An original two-sided glass epoxy through hole board has been prepared and in the open area on the right side, a universal area is available for circuit expansion and prototyping. The power supply for the relay drive will be brought in through PICNIC connector CN3 using a power cable to be constructed.

<Picture 1> Peripheral extension options kit

5.1.2 Specifications

* Output connections: Two lines (RB6, RB7), insulated connections based on mechanical relays

* Input connections: Two lines (RB0, RB1), insulated connections based on photoisolators

* Analog inputs: Two lines (RA0, RA1), 0-+5V, 10-bit resolution (0-1023), shared ground on PICNIC side

* External connector board: 8-pin x 2 (CN3,CN4), relay connection output + connection input

* preparation of universal area for circuit expansion (DIP21x6)

Power voltage: DC12V (supplied through PICNIC-CN3)

5.1.3 Circuit Diagram

<Figure 1> Circuit diagram (click to display PDF file)

5.1.4 Connector pin layout

CN1: Power connector

CN2・ PICNIC connection terminal
* Same as PICNIC-CN2. pin14-26 are 5V type ground on PICNIC side

CN3: Output terminal for relay connection

CN4・ Connection input, analog input terminal (note that on the circuit board, pin 8 is on the left side)

5.1.5 List of components

●Purchase

Available through the GrassPoint shop. Students should purchase the materials individually.

【Item number：PIC0002】
IT Exercises Peripheral Extenstion Options Kit for PICNIC
Price： 8,000 points （shipping and handling fee not included）

→Purchase from here

Summary of materials delivered（packaged）
・Double sided throughhole circuit board, components set
・Connection cable for PICNIC kit external connector （connector crimped）
・Electronic buzzer, security switch, zero pressure socket, PIC microcomputer for operation checks

●Materials needed for constructing the kit

This kit contains relatively few parts and the conditions for soldering on the double sided throughhole board are good so for experienced users, constructing the kit will take 15 minutes to 1 hour. The following materials will be needed.

・needle nose pliers
・nipper
・soldering iron
・solder with resin
・minus screwdriver

If available, the following items will also be useful.

・Solder vacuum plungers （necessary when removing components that have been soldered incorrectly）
・scissors（useful in carefully removing electronic parts from their packaging）
・wire strippers （to remove the covering of wires without damaging the wire metals）
・soldering iron stand（improve work efficiency）
・tester（useful in checking resistance, wire connections, power voltages, etc.）

＜Picture 2＞ Materials needed for kit construction + other useful tools, if available.

The tools pictured here are the items I particularly like and often use. For your reference, I will list the makers and item numbers below （from top left）

・Miniature needle nose pliers：HOZAN　P-36
・Miniature nippers：HOZAN　N-31
・±Changeable screwdriver set：HOZAN D-8/D-4
・Solder vacuum plunger：goot GS-108
・Scissors：Maker unknown（purchased at local home development store）
・Single wire （extra thin）wire stripper：HOZAN P-952
・Insulated soldering iron：goot KS-30R（30W）
・Soldering iron stand：goot ST-76
・Solder with resin：Senju Metal Industry sparkle solder φ1.0mm × 100m roll

●Construction

Component packaging／Construction image／External view of components／Construction procedure

5.4.1 Component packaging

The components, cables, etc. included in the kit are as follows:
・Double sided throughhole circuit board, components set
・Connection cable for PICNIC kit external connector （connector crimped）
・Electronic buzzer, security switch, zero pressure socket, PIC microcomputer for operation checks

These items are divided and packaged in a number of bags.

＜Picture 3＞ Components, cables, etc. included in the kit.

When you remove these items from the packages, particularly small components (for example: MOLEX pin contacts, etc.） can be blown away by the wind. Before that happens, it is a good idea to keep the components organized in a tray as shown below.

＜Picture 4＞ Organize components in a tray.（Example using HOZAN B-40 parts tray）

5.4.2 Construction image

＜Picture 5＞ Construction image （component side：click to display larger image）.

＜Picture 6＞ Construction image （soldering side）

5.4.3 External view of components

【Circuit board components】

	CN1：power connector：Molex　5045-02A：1
	CN2：pin header：Hirose　HIF3H-26PB-2.54DSA：1
	CN3,4：terminal plate for circuit board：Sato　ML-35B 8P：2
	R1～6：resistors：carbon 1/4W 100Ω、4.7KΩ、1KΩ：2 each
	C1,2：capacitors：vertical electrolytic capacitors　10V 47μF：2
	D1,2：diodes：1E10 1A：2
	K1,2：relays（1ch connection）：Omron　G5LE-1　DC12V：2
	U1,2：photocoupler：Toshiba　TLP521-2：2
	IC socket：KEL　ICC05-008-360T　8P：2
	spacers：Logy　SBB-311（with 3mm nuts）：4

【　Peripheral components　】

	crimp type ribbon connectors：Hirose　HIF3BA-26D-2.54R：2（ribbon cables：26 wire flat 20cm：1, crimped）
	power connector：Molex　5102－02：2, connector contacts: Molex　5103：4
	cables：0.3mm strands red, black　1m：1 each
	electronic buzzer：Matsushita 　EB-2132　DC12V 15mA：1
	security switch：Delcatec　MS-102（OFF type）：1
	zero pressure socket：TEXTOOL　40P：1
	PIC microcomputer：PIC-16F877-20/P：1

5.4.4 Construction procedure

（１）Verification of components

First, compare the items delivered with the parts list and verify that all of the necessary components are there.

（２）Connecting components to the circuit board

※When connecting the components, things will generally work out OK if you connect the shorter components first.

(a) Resistors：R1→R2→…→R6　
　Video (6:45) 　

(b) Diodes：D1→D2　
　Video (2:21) 　

(c) IC socket：U1→U2　
　Video (2:04) 　

(d) Terminal plate：CN3→CN4　
　Video (1:23) 　

(e) 26pin power connector header：CN2→CN1　
　Video (4:06) 　

(f) Electrolytic capacitor：C1→C2　
　Video (2:34) 　

(g) Relay：K1→K2　
　Video (2:20) 　

(h) Spacers, screws（4）　
　Video (1:51) 　

（３）Construction of power cable, terminal plate bypass cable

・Power cable： After soldering the cables:0.3mm strands (red, black) cut into 20 cm lengths to the connector contact (Molex 5103), insert firmly into the power connector (Molex 5102－02). The connector #1 pin will be red (+).
　Video (8:40) 　

・Terminal plate bypass cable：Strip back the covering of the cables: 0.3mm strands (red, black) cut into 5-10 cm pieces and plate them with solder.　
　Video (1:45) 　

（４）Connecting the cable to the security switch

・Security switch On the switch terminal plate（Delcatec MS-102）, fix the remaining cables： 0.3mm strands (red, black). It will be handy to plate the loose ends of the wires with solder.
　Video (6:20) 　

●View of constructed circuit board

＜Picture 7＞ External view of completely constructed kit.

＜Picture 8＞ View from circuit board side.（1）

＜Picture 9＞ View from circuit board side.（2）

＜Picture 10＞ View from circuit board side.（3）

＜Picture 11＞ View from circuit board side.（4）

●Operation testing

Preparation of test environment／Test of remote I/O control （1）／Test of remote I/O control （2）／Test of analog input circuit

5.7.1 Preparation of test environment

【Procedure for removing jumper JP1 on the PICNIC circuit board】（added May 30, 2005）

（０）Currently, the jumper JP1 at the top left of the PICNIC board is on 1-3:2-4, but this should be removed（it is a good idea to hang the jumper on the bottom pins 1, 2）.：※Reason: RB0, RB1 of the PIC microcomputer are shared with the serial port flow control lines, but these are not necessary in this exercise.

【Connection of PICNIC⇔peripheral extension options】

（１）Connection with PICNIC： The power connector and flat cable are connected together. Be particularly careful in connecting the PICNIC side power connector correctly! (#1 pin on the left side is red +)

＜Picture 12＞ Connection of PICNIC⇔peripheral extension options（peripheral extension board side）

＜Picture 13＞ Connection of PICNIC⇔peripheral extension options（PICNIC side）

【Connection between the terminal plate bypass lines and the electronic buzzer, security switch】

（２） Bypass lines to the terminal plate：Connect terminal plate 1⇔2 pins on CN3 （DC+12V⇔RB7-COM）with the bypass lines.

＜Picture 14＞ Bypass line connection to terminal plate CN3.

（３）Electronic buzzer wiring： Connect terminal plate CN3 pin 3 （RB7-T）and pin 8 （GND）to the plus and minus terminals of the electronic buzzer, respectively.

＜Picture 15＞ Wiring of electronic buzzer and CN3.

（４）Connection of security switch： Open the cover of the terminal plate on the security switch side and fasten one of the cables with the screw (nonpolar). Next, connect the other to terminal plate CN4 pin 1 （RB0-TA） and pin 2（RB0-TB）(these are also nonpolar).

＜Picture 16＞ Connection between security switch and terminal plate.

＜Picture 17＞ Connection to terminal plate CN4.

【Overall connections including PICNIC】

＜Picture 14＞ Connections completed between peripheral components and terminal plate.

5.7.2 Test of remote I/O control （1）

From among the remote I/O operations of the PICNIC, we will control the digital output of（RB7） and sound off the electronic buzzer connected to that port.

（１）Complete 5.7.1(a) Wiring of the terminal plate bypass lines to the electronic buzzer described earlier. （electronic buzzer will be connected to the relay connection of RB7）

（２）Set up a PC and network environment for operation checks and prepare to perform remote PICNIC I/O from a web browser.

（３）From the remote I/O control screen, change the output value of digital output （RB7）from L→H.

（４）Following the change, verify that you hear the sound of the mechanical relay operating （a clicking sound of the solenoid moving） and that the electronic buzzer turns on. Also, the buzzer included in this exercise is a 「Horohoro」（hit item from Matsushita Denko） often used in door alarms.

（５）From the remote I/O control screen, change the output value of digital output （RB7） from H→L and turn off the buzzer.

＜Practice exercise １＞
Turn on the electronic buzzer using control of digital output （RB6）. How should the wiring between terminal plate CN3 and the electronic buzzer be changed?

＜Practice exercise ２＞
Verify the flow of operation starting from the PICNIC side digital output （RB6,7）to the photoisolator→mechanical relay turning on by tracing the path on the circuit diagram. Why have we matched the digital output logic（H/L）and the relay connection output logic （T/F）to each other?

※What to do if you are having problems with the sound of the electronic buzzer 「Horohoro」being too loud：
→you can control the volume by putting a piece of cellophane tape on the slit near the top where the sound emits.
　If you remove it all together, the "joy" in completing the program will be diminished so let's not do that. ;-P

5.7.3 Test of remote I/O control （2）

Next, from among the remote PICNIC I/O controls, let us monitor the digital input （RB0）value and check the status of the security switch connected to that port.

（１）Complete the 5.7.1(b) Security switch connection described earlier. （security switch connected to RB0 input connection）

（２）Set up a PC and network environment for operation testing and prepare to perform remote PICNIC I/O control from a web browser.

（３）First, disconnect the magnet portion of the security switch from the switch（＝door open state）.

（４）Display the remote I/O control screen and verify that the input value of the digital input （RB0） is "L".

（５）Next, connect the magnet portion of the security switch to the switch（＝door closed state）.

（６）Redisplay (reload) the remote I/O control screen and verify that the input value of the digital input （RB0） has changed to "H".

＜Practice exercise ３＞
Let us detect the state of the security switch by monitoring digital input （RB1）. How should we change the wiring between terminal plate CN4 and the security switch?

＜Practice exercise ４＞
Follow the flow of operation from the security switch→terminal plate CN4→photoisolator→PICNIC side digital input （RB0,1） and trace the path on the circuit diagram. Why have we matched the state of the security switch connection （Close/Open） with the digital input logic （H/L）?

5.7.4 Test of analog input circuit

Finally, let us read the values of the PICNIC remote I/O analog input （RA0） and check the voltage of the power (direct current) connected to that port. In the example below, we will connect the PICNIC side power DC+5V directly to RA0 and obtain the analog values （around 1023）.

（１）Using the terminal plate bypass cable, connect terminal plate CN4 pin 8 （DC+5V） with pin 6 （RA0）.

（２）Set up a PC and network environment for operation testing and prepare to perform remote PICNIC I/O control from a web browser.

（３）Display the remote I/O control screen and verify that the input value of the analog input （RA0） is around "1023"（5V）.

（４）Next, connect terminal plate CN4 pin 5（GND） and pin 6 （RA0）.

（６）Redisplay (reload) the remote I/O control screen and verify that the input value of the analog input （RA0）is around "0" （0V）.

＜Practice exercise ５＞
By using the analog input function, measure the open voltage of dry cell or button batteries you have handy. For example, to measure voltage from port RA1, how should we connect the terminal plate and battery to be measured? Also, from the analog value obtained（10bit: 0～1023）, how can we calculate the open voltage of the battery （in units of 0.1V）?（Hint：the temperature coefficient of the RA5 Celsius linear temperature sensor is +10.0mV/℃.）

wasaki@cs.shinshu-u.ac.jp
Copyright(c) 2005 Katsumi Wasaki. All rights reserved.