3/24/2012

CSULB REPRAP

RAMPS SHIELD SOLDERING TUTORIAL GUIDE

David Tran

RAMPS SHIELD SOLDERING TUTORIAL GUIDE

Contents
Warning......................................................................................................................................................... 1 Definitions ..................................................................................................................................................... 1 Unpack and Inspect package ........................................................................................................................ 2 Recommended soldering order .................................................................................................................... 4 Solder (2) 8pos, 1row male header pins to each of the Pololu Stepper Driver ........................................ 4 Solder (7) 3pos, 2row male header pins for the step selection ................................................................ 5 Solder (6) 4pos, 1row male header pins for the steppers and end stops................................................. 6 Solder (4) 8pos, 1row and (2) 24pos, 1row Female header pins for the drivers ...................................... 7 Solder Diode D2 ........................................................................................................................................ 7 Solder Fuse 1 and 2 ................................................................................................................................... 8 Solder Mosfet Q1, Q2, and Q3 .................................................................................................................. 8 Solder terminal block connector 1 and 2 .................................................................................................. 8 Solder male header pins to connect the shield to the Arduino Mega. ..................................................... 9 Soldering the reset button ...................................................................................................................... 10 Final step ..................................................................................................................................................... 10

Warning
Soldering is fun, but is tedious and requires a lot of patience. Use the following tutorial at your own risk. Have proper ventilation. Solder fumes can be noxious and poisonous. The soldering iron is a tool, handle with care. Be sure that you are comfortable with soldering. If uncomfortable, ask for help. !!!Do not touch the non-insulated part of the soldering iron!!! Severe burns will result if the iron is handled incorrectly. As a precaution, wear safety glasses when soldering or cutting the leads of the component. Note: do not let the hot solder iron touch any components not intended for. Doing so may melt the plastic/component. ESD: Electro Static Discharge. Any electronics that is in the pink package is susceptible to ESD. It is best to ground yourself before touching any electronics.

Definitions
When referring to the header pins, they will be in the following formats: x pos, n row or x by n. For instance, a 36 pin header that is divided into 2 rows is called 18pos, 2row or 18 by 2. In the case of the 18 by 2, each row consists of 18 positions and there are 2 rows, therefore there are a total of 36 pins. PCB stands for Printed Circuit Board. PCB will be used to reference the shield/board.

Tack is a welding term. However, when the user is told to tack, he or she should solder only one pin. This allows the user to break the tack if necessary.

Unpack and Inspect package

The Ultimachine RAMPS DIY kit should include the following: SMD Pre-populated RAMPS v1.4 Shield (x1)

Pololu Stepper Driver Package w/ a heat sink and a 16 by 1 row of male header pins (x4) Microswitch SS-3GL13PT (x3) 18pos, 2row pin header (x1) 3pos, 2row pin header (x8) * using only 7 for this tutorial 24pos, 1row pin header (x1) 8pos, 1row pin header (x5) 6pos, 1row pin header (x2) * using only 1 for this tutorial 4pos, 1row pin header (x6) 24pos, 1row female pin header (x2) 8pos, 1row female pin header (x4) 6 pin terminal block (x1) 4 pin fixed terminal block (x1) 4 pin pluggable terminal block (x1) Shorting (jumper) block 2.54mm (x15) Tactile switch B3F-3100 (x1) Fuse MF-R500 (x1) * small Fuse MF-R1100 (x1) * large Diode 1N4004 (x2) * using only 1 for this tutorial STP55NF06L - MOSFET (x3) Heatsink w/ nut,bolt (x1) Arduino Mega (in package) (x1) Standard USB cable (x1)

Recommended soldering order

Steps appears to be redundant, however, it is the same idea, just for different components.

Solder (2) 8pos, 1row male header pins to each of the Pololu Stepper Driver
a. Use a pair of pliers to break the 16 by 1 male header pins into (2) 8 by 1 headers. b. Insert the 8 by 1 header into the holes on the Pololu Stepper Driver. The shorter end of the pin goes into the driver PCB. The pins should be inserted on the side of the driver with the printing/labels. c. Set up a rig to hold the male header pin using the (2) 24x1 female header. i. This allows the header pins to be aligned.

d. e. f. g.

h.

i. j. k.

Pololu driver was taken off for a picture before soldering. Apply minimal pressure to hold the header pin flush to the PCB. Flip the board over while holding on to the header. Tack solder a pin on the header for each side. If the header looks aligned and is flush, solder the opposing joint. Meaning, if the first pin was tack soldered and the part is aligned, go ahead and solder the last pin. i. This prevents the parts from moving while soldering. If the header pins are not straight, re-heat the single tack from step f. and adjust the header. Once done, go back to step g. i. By tacking only one pin, it is easier to reposition if needed. Remove the 24 by 1 female header pin alignment brace. Solder the remaining pins. Repeat until all (4) Pololu drivers are complete.

Solder (7) 3pos, 2row male header pins for the step selection
a. Set up a rig to hold the male header pin using the (2) 24x1 female header. i. This allows the header pins to be aligned.

(2) 24 by 1 holding (2) 3 by 2 into position for soldering. b. c. d. e. Apply minimal pressure to hold the header pin flush to the shield PCB. Flip the board over while holding on to the header. Tack solder a pin on the header. If the header looks aligned and is flush, solder the opposing joint. Meaning, if the first pin was tack soldered and the part is aligned, go ahead and solder the last pin. i. This prevents the parts from moving while soldering. f. If the header pins are not straight, re-heat the single tack from step d. and adjust the header. Once done, go back to step e. i. By tacking only one pin, it is easier to reposition if needed. g. Remove the 24 by 1 female header pin alignment brace. h. Solder the remaining pins. i. Continue until all (7) 3 by 2s are soldered. Location of the 3 by 2 male headers

Solder (6) 4pos, 1row male header pins for the steppers and end stops
a. Set up a rig to hold the male header pin using the (2) 24x1 female header. i. This allows the header pins to be aligned. ii. Picture not available, same idea as above. b. Apply minimal pressure to hold the header pin flush to the shield PCB. c. Flip the board over while holding on to the header. d. Tack solder a pin on the header. e. If the header looks aligned and is flush, solder the opposing joint. Meaning, if the first pin was tack soldered and the part is aligned, go ahead and solder the last pin. i. This prevents the parts from moving while soldering. f. If the header pins are not straight, re-heat the single tack from step d. and adjust the header. Once done, go back to step e. i. By tacking only one pin, it is easier to reposition if needed. g. Solder the remaining pins. h. Continue until all (6) of the 4 by 1 header are soldered.

Location of the 4 by 1 male headers

Solder (4) 8pos, 1row and (2) 24pos, 1row Female header pins for the drivers
a. By this section of the tutorial, there should be no more male header pins to solder on the top of the shield. The 24 x 1 headers can no longer be used to align the headers. Set up a rig to hold the female header pin using the drivers itself to align the headers. i. This allows the header pins to be aligned with the driver.

Pololu Stepper drivers aligning the female header pins b. c. d. e. Apply minimal pressure to hold the header pin flush to the shield PCB. Flip the board over while holding on to the header/ driver. Tack solder a pin on the header. If the header looks aligned and is flush, solder the opposing joint. Meaning, if the first pin was tack soldered and the part is aligned, go ahead and solder the last pin. i. This prevents the parts from moving while soldering. f. If the header pins are not straight, re-heat the single tack from step d. and adjust the header. Once done, go back to step e. i. By tacking only one pin, it is easier to reposition if needed. g. Once both ends of the female headers are tacked or solder, remove the stepper drivers from the female headers. h. Solder the remaining pins. i. Continue until all female headers for the drivers are soldered.

Solder Diode D2
a. Using a pair of pliers, bend the diode leads close enough so that it will fit through the holes. b. Be sure that the diode is in the correct position. Stripe to Stripe. !!!Polarity matters!!! c. Insert the diode into location D2 and solder it. d. Safely cut the expose leads that remains. e. Note: Diode D1 exists. D1 allows the Arduino Mega to draw its power through the RAMPS power supply. (Optional)

Solder Fuse 1 and 2

a. Fuse 1 and 2 are straight forward, there is no polarity. b. The smaller fuse goes into location F1. Fuse value face the stepper drivers. c. The larger fuse goes into location F2. Fuse value faces the opposite direction toward the terminal connector. d. The silkscreen or label on the board shows the layout/footprint of the component. e. Solder both fuses. f. Safely cut the expose leads that remains.

Location of the two fuses, F1 and F2

Solder Mosfet Q1, Q2, and Q3

a. b. c. d. e. f. Like the fuse and diode, insert the Mosfet onto the PCB shield. The bold solid line on the silkscreen/layout indicates the direction to install the Mosfet. The bold solid line should align with the metal backing of the Mosfet. Tack solder a pin on the Mosfet. Make alignment and changes. Solder the remaining pins of the Mosfets.

Location of the three mosfets, metal tab aligns with white line

Solder terminal block connector 1 and 2

a. b. c. d. e. f. g. h. Insert the 4-pin fixed terminal block into the board. Tack solder one of the pins. Ensure that the part is flush and centered. Solder the remaining pins. Insert the 6-pin terminal block into location label D8-D10. Again, tack solder a single pin on the terminal block. Then align the terminal block if necessary. Solder the remaining pins.

i.

Note: the 4-pin terminal block protruding pins on the bottom of the shield may hit the DC jack on the Arduino. This may require some trimming of the leads later.

Location of the two terminal blocks

Solder male header pins to connect the shield to the Arduino Mega.
a. This step requires (1) 18 by 2, (5) 8 by 1, and (1) 6 by 1 male headers. b. Insert the 18 by 2 header into the Arduino Mega. c. Insert (4) 8 by 1 male header into all the remaining headers on the Arduino Mega with the exception of the 8-pin female header nearest to the DC JACK and the 10-pin female header nearest to the USB port. d. Insert a 6 by 1 header into the remaining 8-pin female header. The first pin should be the furthest away from the DC JACK. See picture. e. Insert an 8 by 1 male header in the 10-pin female header. The first pin should be the furthest away from the USB port. See picture. f. Sandwich the RAMPS shield on top of the Arduino with header pins sticking out. g. Carefully guide all the header pins into the holes on the RAMPS shield. They should line up. h. This is why we want to use the fixed header pins to align the headers to be solder. If we solder the header without aligning. We will have a hard time installing the shield later on. i. Align and tack the necessary pins. a. This means that each header should get at least two of its pins soldered. j. Apply enough solder that would allow the RAMPS shield to be pulled off the Arduino. k. Take off the shield. There may be excessive tension on the headers. Gently pry evenly until the shield comes off. l. Once the shield is off the Arduino, go back and finish soldering the remaining pins. Add more solder if necessary. m. Leave the shield off.

Soldering the reset button

a. b. c. d. Insert the push button into the PCB. It will only fit one way. Align the button and tack solder the pins Finish soldering the button

Location of the reset push button

Final step
a. Use flux remover to clean away and flux/rosin residue. b. Install the shield onto the Arduino. It should slide right in. c. Congratulations! You should now have a working RAMPS shield.

Final RAMPS Shield