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Casper Electronics Version 2.1 Updated January 7th, 2009 These diagrams will serve as a step-by-step document to aid in the assembly of your Drone Lab! To start off, you are going to be needing a number of materials and tools: - Soldering Iron A cheap radio shack unit will technically work, but a nicer temperature controllable iron will save time and frustration. - Solder Whatever type you prefer, small gauge solder helps avoid excessively large joints. - Wire Cutters The type with the flat cutting edge for nipping leads off close to the board. - Needle Nose Pliers - Flathead Screwdriver - Solder Wick Extremely helpful when removing shorts / de-soldering joints. - Multi-Meter Extremely helpful in debugging. Get one that beeps when it detects electrical continuity, and learn how to use all the functions! Here’s the parts that are required to build a functional Drone Lab. They are all included in the kit. In the following pages you’ll see pictures of each component. If you purchased a kit, please make sure you have all of the components shown. There was great effort paid to making sure all of the kits went out complete, but if indeed a mistake was made contact us directly. Note, if you received an enclosure, you should have received a hardware bag that includes nylon standoffs. Resistors Capacitors Switches Jacks + Power 100 1 10pF 2 Slide DPDT 10 1/8" Mono w/ Switch 3 470 1 1000pF 1 Total 10 5.5mm DC w/ Switch 1 1k 5 2200pF 2 1/4" Mono 2 2.2k 8 4700pF 3 9V 1 10k 14 .022uF 4 10k 4 PC Mount Bat Box 1 22k 6 .1uF 16 50k 12 Total 8 51k 2 1uF 1 1M 9 56k 1 2.2uF 4 Total 25 100k 18 10uF 10 330k 4 100uF 3 470k 1 220uF 1 Red LED 6 1M 4 Total 47 8.2V Zener 1 4.7M 2 4148 1 Total 67 1N4001 3 ICs + Sockets 14 Pin DIP Sockets TLC556 LM7809 CD 40106 TL074 Total 4 2 1 1 1 9 Total 9 Transistors 2N3904 7 2N3906 8 Total 15 Potentiometers Diodes Values of component numbers, helpful if you’re building off the board silkscreen. R49 R54 R4 R39 R41 R51 R56 Resistors 100 R52 470 R53 1k R6 1k R2 1k R3 1k R5 1k R22 51k 51k 56k 100k 100k 100k 100k C39 C40 C33 C26 C32 C24 C30 Capacitors 10pF C3 10pF C4 1000pF C5 2200pF C6 2200pF C25 4700pF C27 4700pF C28 10uF 10uF 10uF 10uF 10uF 10uF 10uF Potentiometers BPF_F1 10k BPF_F2 10k DIST_AMNT 10k LPF_CUT 10k BPF_BAL 50k DIST_VOL 50k FPITCH1 50K R1 2.2k R23 100k C31 4700pF C34 10uF FPITCH2 50K D8 4148 R8 2.2k R24 100k C8 .022uF C38 10uF FPITCH3 50K D9 1N4001 D1 D2 D3 D4 D5 D6 D7 Diodes Red LED Red LED Red LED Red LED Red LED Red LED 9V Zener C_IN C_OUT C_THRU DC_JACK INPUT OUTPUT Battery Jacks + Battery 1/8" Mono w/ Switch 1/8" Mono w/ Switch 1/8" Mono w/ Switch 5mm w/ Switch 1/4" Mono 1/4" Mono 9V Battery Box PC Mount R9 2.2k R25 100k C9 .022uF C42 10uF FPITCH4 50K D10 1N4001 R16 2.2k R34 100k C10 .022uF C2 100uF IN_VOL 50k D11 1N4001 R21 2.2k R35 100k C11 .022uF C29 100uF MASTER_VOL 50k R29 2.2k R36 100k C12 .1uF C43 100uF VOL1 50k R33 R47 R7 R14 R15 R18 R20 2.2k 2.2K 10k 10k 10k 10k 10k R37 R38 R40 R46 R59 R60 R61 100k 100k 100k 100K 100k 100k 100k C14 C17 C19 C20 C21 C22 C23 .1uF .1uF .1uF .1uF .1uF .1uF .1uF C1 VOL2 VOL3 VOL4 CPITCH1 CPITCH2 CPITCH3 CPITCH4 50k 50k 50k 1M 1M 1M 1M Q1 Q12 Q14 Q15 Q3 Q6 Q9 R26 10k R62 100k C35 .1uF DIV1 1M Q10 2N3906 R27 R28 R32 10k 10k 10k R17 R19 R30 330k 330k 330k C36 C37 C41 .1uF .1uF .1uF DIV2 DIV3 DIV4 1M 1M 1M Q11 2N3906 Q13 2N3906 Q2 2N3906 U1 U2 R43 R48 R57 10k 10K 10k R31 R42 R64 330k 470k 1M C44 C45 C46 .1uF .1uF .1uF RATE 1M Q4 Q5 Q7 2N3906 2N3906 2N3906 U3 U4 U5 TLC556 TLC557 TL074 R58 R63 R10 R11 10K 10K 22k 22k R65 R66 R67 R50 1M 1M 1M 4.7M C47 C7 C13 C15 .1uF 1uF 2.2uF 2.2uF Q8 2N3906 Sockets 14 Pin DIP x 4 R12 22k R55 4.7M C16 2.2uF R13 R44 22k 22k C18 2.2uF R45 22K 220uF Transistors 2N3904 2N3904 2N3904 2N3904 2N3904 2N3904 2N3904 Switches SW1 POWER SW2 INVERT1 SW3 T_OFF1 SW4 SW5 SW6 SW7 SW8 SW9 SW10 INVERT2 T_OFF2 INVERT3 T_OFF3 INVERT4 T_OFF4 TREM OFF ICs & Sockets LM7809 CD 40106 Which component is which value. R49 R54 R4 R39 R41 R51 R56 Resistors 100 R52 470 R53 1k R6 1k R2 1k R3 1k R5 1k R22 51k 51k 56k 100k 100k 100k 100k C39 C40 C33 C26 C32 C24 C30 Capacitors 10pF C3 10pF C4 .001uF C5 2200pF C6 2200pF C25 4700pF C27 4700pF C28 10uF 10uF 10uF 10uF 10uF 10uF 10uF Potentiometers BPF_F1 10k BPF_F2 10k DIST_AMNT 10k LPF_CUT 10k BPF_BAL 50k DIST_VOL 50k FPITCH1 50K R1 2.2k R23 100k C31 4700pF C34 10uF FPITCH2 50K D8 4148 R8 2.2k R24 100k C8 .022uF C38 10uF FPITCH3 50K D9 1N4001 10uF FPITCH4 50K IN_VOL MASTER_VOL VOL1 50k 50k 50k Transistors Q1 2N3904 Q2 2N3906 SW1 SW2 SW3 POWER INVERT1 T_OFF1 VOL2 VOL3 VOL4 CPITCH1 CPITCH2 CPITCH3 CPITCH4 50k 50k 50k 1M 1M 1M 1M Q3 Q4 Q5 Q6 Q7 Q8 Q9 SW4 SW5 SW6 SW7 SW8 SW9 SW10 INVERT2 T_OFF2 INVERT3 T_OFF3 INVERT4 T_OFF4 TREM OFF D1 D2 D3 D4 D5 D6 D7 Diodes Red LED Red LED Red LED Red LED Red LED Red LED 9V Zener C_IN C_OUT C_THRU DC_JACK INPUT OUTPUT Battery Jacks + Battery 1/8" Mono w/ Switch 1/8" Mono w/ Switch 1/8" Mono w/ Switch 5mm w/ Switch 1/4" Mono 1/4" Mono 8.2V Battery Box PC Mount R9 2.2k R25 100k C9 .022uF C42 R16 R21 R29 2.2k 2.2k 2.2k R34 R35 R36 100k 100k 100k C10 C11 C12 .022uF .022uF .1uF C2 100uF C29 100uF C43 100uF R33 R47 R7 R14 R15 R18 R20 2.2k 2.2K 10k 10k 10k 10k 10k R37 R38 R40 R46 R59 R60 R61 100k 100k 100k 100k 100k 100k 100k C14 C17 C19 C20 C21 C22 C23 .1uF .1uF .1uF .1uF .1uF .1uF .1uF R26 10k R62 100k C35 .1uF DIV1 1M Q10 2N3906 R27 R28 R32 10k 10k 10k R17 R19 R30 330k 330k 330k C36 C37 C41 .1uF .1uF .1uF DIV2 DIV3 DIV4 1M 1M 1M Q11 2N3906 Q12 2N3904 Q13 2N3906 U1 U2 R43 10k R31 330k C44 .1uF RATE 1M Q14 2N3904 U3 TLC556 R48 R57 10K 10k R42 R64 470k 1M C45 C46 .1uF .1uF Q15 2N3904 U4 U5 TLC557 TL074 R58 R63 R10 R11 10K 10K 22k 22k R65 R66 R67 R50 1M 1M 1M 4.7M C47 C7 C13 C15 .1uF 1uF 2.2uF 2.2uF Sockets 14 Pin DIP x 4 R12 22k R55 4.7M C16 2.2uF R13 R44 22k 22k C18 2.2uF R45 22K C1 220uF Switches 2N3904 2N3906 2N3906 2N3904 2N3906 2N3906 2N3904 ICs & Sockets LM7809 CD 40106 It is highly recommended that you sort the bag of resistors into piles before proceeding to assembly. Each diagrams is a screenshot of the board with the component for that page highlighted. With the components sorted, assembly will be more efficient. Resistors 100 1 470 1 1k 5 2.2k 8 10k 14 22k 6 51k 2 56k 1 100k 18 330k 4 470k 1 1M 4 4.7M 2 Total 67 The Resistor Color Code: For the kit resistors, ignore the 3rd Band. -Note: For those who purchased kits, the kit ships with 5 values of capacitor that look almost identical. Written on them is the capacitor code, but the kits were assembled in such a way that the quantity of each of these similar-looking capacitors is also an indicator. -Another Note: The radial capacitors (220, 100, 10, 2.2, and 1 uF) should be inserted so the longer lead goes through the square hole. THIS IS DIFFERENT FOR THE LEDs. 220uF Capacitors 10pF 2 1000pF 1 2200pF 2 4700pF 3 .022uF 4 .1uF 16 1uF 1 2.2uF 4 10uF 10 100uF 3 220uF 1 Total 47 100uF 10uF 2.2uF 2200pF .1uF 1uF 1000pF 10pF .022uF 4700pF The transistors’ physical shape should match the silkscreen of the component from the top. Otherwise the transistor will not function properly. Note: The transistors should be installed before the switches. Transistors 2N3904 7 2N3906 8 Total 15 The 1N4001 has the thickest leads, and the 4148 has tape on the ends. Diodes Red LED 6 8.2V Zener 1 4148 1 1N4001 1 Total 9 NOTE: The longer lead of the LED should go in the CIRCLE hole. - This is different from the capacitors - -Tip: Try and solder the support lugs for extra durability! Switches Slide DPDT 10 Total 10 -Note: After the potentiometer has been inserted into the board, the legs can be bent apart to ensure a strong hold of the board. This will keep torsion load from twisting the knob from loading the active electrical solder joints. Potentiometers 10k 4 50k 12 1M 9 Total 25 Jacks + Power 1/8" Mono Audio Jack w/ Switch 3 5.5mm DC Power Jack w/ Switch 1 1/4" Mono Audio Jack 2 PC Mount Battery Box 1 9V Battery 1 Total 8 -NOTE Solder the sockets in, and then put 14 Pin ICs into the sockets to avoid overheating the ICs. All ICs should have their notch on the left. ICs + Sockets 14 Pin DIP Sockets 4 LM7809 TLC556 2 CD 40106 1 TL074 1 Total 8 The Drone Lab was designed to be simple and expressive. It was also designed to be modified and hacked. There is a small area to the left of the audio jacks for custom circuitry, and many breakout points where wires can be soldered in, and traces can be cut to enable users to modify the signals. The Drone Lab was designed to be a fully functional synthesizer using nothing but the board and components. However, the circuitry can be housed in any number of ways, and custom switches, potentiometers, and LED indicators can be added by the user. It’s your Drone Lab, do what you want with it! This section of documentation will show some points we thought would be useful to have easy access to, and provided breakout holes for wires for just that reason. If you come up with any interesting modifications, please share them with us and the rest of the Drone Lab community on the forums! Happy Hacking! For Version 1.2 of the board, we have provided a mid-board breakout of all connections running to the potentiometers of the Drone Lab. This allows for the board to be cut in half for more flexible enclosure designs. Below is a labeling system that will help with running flying wires to potentiometers. When in doubt, follow the traces or use a multi-meter! 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 9 10 GND DIST_VOL-3 V+ VOL1-3 CPITCH1-1&2 FPITCH1-3 CPITCH2-1&2 VOL2-3 FPITCH2-3 CPITCH3-1&2 9 10 11 12 11 12 13 14 15 16 17 18 19 20 V+ VOL3-3 FPITCH3-3 CPITCH4-1&2 V+ VOL4-3 FPITCH4-3 DIV4-3 DIV3-3 DIV2-3 13 14 15 21 22 23 24 25 26 27 28 29 30 16 17 18 DIV1-3 DIST_VOL-2 DIST_AMNT-2 LPF-1&2 LPF-3 IN_VOL-3 IN_VOL-2 VOL4-2 VOL3-2 VOL2-2 19 20 21 22 23 24 25 26 31 32 33 34 35 36 37 38 39 27 28 29 30 31 32 33 34 VOL1-2 MASTER_VOL-2 BPF_BAL-3 BPF_F2-3 BPF_F1-3 BPF_F1-2 BPF_BAL-1 V+ GND If you cut off the bottom, don’t forget about R63, C42 & C43! 35 36 37 38 Sample Pot (TOP VIEW) 1 2 3 39 There are two different hardware kits. The first is what ships with every Drone Lab, and the second is for the Laser Cut housing plates. Housing Hardware ( Component(Location) ) Kit Hardware ( Component(Location) ) 5/8” Flat Screw (Battery Box) 3 5/8” Flat Screw (Battery Box) 3 1 1/4“ Flat Screw (Corners) 4 1/2“ Round Screw (Corners) 4 1“ Flat Screw (Sides, Center) 3 #4 Lock Washer (Corners) 4 #4 Nuts (Corners In Feet, Battery Box, Sides, Center) 14 #4 Nuts (Corners In Feet, Bat Box) 7 #4 Lock Washer (Corners, Sides, Center) 7 Rubber Feet (Corners, Bottom) 4 Total 22 Vinyl Standoffs (Corners, Sides, Center) 7 Rubber Feet (Corners, Bottom) 4 Total 42 This isn’t the easiest to assemble kit out there. Still, with a little patience and attention to detail, especially in creating great solder joints, the unit should be able to be built within 8 hours. If it doesn’t work the first time do not despair, our units didn’t work the first try either. Some Tips for Debugging: - Look for missing or loose solder joints, cold solder joints can drive you nuts! Look to heat up the surfaces of both the lead and pad such that the solder forms a concave curve to the surfaces. - When in doubt use your Multi-Meter! Check for continuity where there should be, and where there shouldn’t be. - Follow the circuit schematic of failing systems. Look for abnormalities of continuity or missing / wrong direction components. - Keep Hope Alive. You’ll get it working soon enough! Remember to have fun, you’re building an analog synthesizer! Thanks again for your business, we hope you enjoy your Drone Lab. If you have any questions, comments, or content, share it on the forums! http://www.casperelectronics.com/ghostwizard/