Build: FPD

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Falcon Pixlenet/DMX 512 Dongle Assembly Manual (V1)

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Introduction

You have made a wise decision to build the Falcon FPD Daughter board for the Falcon FPP system. We believe you will be very pleased with what this hardware can do for you.

The Falcon FPD is a daughter board for the Falcon Pi Player that allows you to output 32k channels. It supports both Pixelnet and DMX output via 12 universes ports (4 universes per RJ-45 Jack) in any combination.

With the addition of this daughter board to the Falcon Pi Player it would be the same capability as 2 EtherDongles, 1 Conductor, and 1 Slave. Along with additional features not available elsewhere.

Before we start assembly of the FPD we want to do two things. First we need to take inventory and make sure we have all the components that should have come with your order(s). Please use static precautions in the handling of sensitive parts. If you are not familiar in them please research on the Internet prior to handling them. You can damage your parts with improper handling!

Take your time building the FPD so it will give you many seasons of trouble free operation. Take care inspecting the solder joints and making sure ALL parts and chips are in the proper orientation as per the silk screen on the PCB.

Preparing To Build

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We assume you found everything in your order and are ready to start.

The PC Board you received should already have two surface mount chips installed on it. All of the components you will be installing are through-hole so no surface mount work will be required.

The next thing we want is to make sure you are up to speed on soldering and electrostatic protection of the components in your kit. If you are not an experienced printed circuit builder I recommend you visit the site:

http://curiousinventor.com/guides/How_To_Solder

And check out their extremely good video on soldering correctly. Even if you are an expert it is a good video to watch.

Another issue you must be aware of is that some electronic components can be damaged easily by electrostatic charges that can build up in you or your equipment. We have all been shocked by walking on carpet and grabbing a door knob before. This is electrostatic charge in action. It takes much less than this to hurt some of our parts. If you are unfamiliar with procedures to protect from this please use the internet to research it before opening your parts up. You can damage your parts with improper handling!

You will need a few tools that do not come with your kit to build the FPD. You will need a good soldering iron. We can not stress enough that a good soldering iron makes a big difference in these projects. The little 15w cheap irons are more apt to hurt your parts by taking too long to get the parts up to soldering temperature than a good iron which can bring it up to temp very fast. Remember it is more how long you keep the part hot than it is how hot you get it within reasonable soldering temperatures. A good soldering iron can be had for very reasonable amounts of money. You can purchase one for $30 to $60 dollars. Most anything that is called a soldering station where there is a temperature control separate from the iron itself will more than likely be fine but make sure it is rated for more than 15 watts.

You will need solder, so get some. We recommend .032 size (0.8mm or 0.7mm) as the larger sizes tend to cause you to put too much solder on. How much? Go ahead and get a 1 lb spool as it’s cheaper in large volume and you will go through it faster than you think. Make sure you are getting rosin core for electronics, they make some solder for plumbing that has acid as the core this is a bad mistake to make.

You will need some work area to work with good lighting. Do not attempt to solder circuit boards in poorly lighted areas. If you wear reading glasses go get them you will want them we promise you. We recommend a set of helping hands like this: Radio Shack or HarborFreight or Amazon.com.

Install the 0.1 uF Ceramic Capacitors

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Install thirty (30) 0.1uf capacitors in their proper location on the board. There is no wrong direction for these.

Solder all these capacitors and trim the leads.

Install the Resistors

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Install two (2) Carbon Film Resistors - Through Hole 4.7K ohms at R2, R4

Install one (1) Carbon Film Resistors - Through Hole 51 ohms at R3

Solder all these resistors and trim the leads.

Install more Capacitors

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Install two (2) Multilayer Ceramic Capacitors MLCC - Leaded 10uF 10volts X5R 10% at C29, C35

Solder all these capacitors and trim the leads.

Install LEDs

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Install one (1) Standard LEDs - Through Hole Red 180mcd 640nm at D2

Install two (2) Standard LEDs - Through Hole Blue 2000mcd 470nm at D3, D4 (Note: Blue LEDs are not installed in the above picture yet)

Note: Longer lead is the positive (+) side.

Solder and trim the leads.

Install the DIP Sockets

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Install eighteen (18) IC Sockets 8P DUAL WIPE DIP

NOTE: Socket orientation - middle notch goes to the right as noted on board silkscreen.

After inserting sockets, solder 1 corner pin in each socket inserted. Reheat that pin and push down on socket to make sure socket is flat with board. Then solder opposite corner pin pushing down as well. This method makes sure your sockets are flush with the board.

Finish rest of socket pins. Lead trimming is not required on these sockets.

Install Push Button Switch

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Install one (1) Pushbutton Switche SHORT TRAVEL SWITCH 6X6 at S1

Install Resistor Networks

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Install three (3) Resistor Networks & Arrays 8PIN 180Ohms at RN2, RN5 & RN8

Install three (3) Resistor Networks & Arrays 8PIN 470Ohms at RN1, RN4 & RN7

On the new v1.03 boards, there are three new Resistor Networks (RN9, RN10, RN11) Recently added to the BOM, they are 120ohm terminating resistors for impedence matching.
They are optional

Install Voltage Regulator & Heat Sink

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Install one (1) - Low Dropout Regulators - LDO 3.3V

and

Install one (1) - Heat Sinks TO-220 HORIZ/VERT (Note: Heat Sink is not shown in photo above yet)

Solder and trim the leads.

Install more Capacitors

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Install two (2) Aluminum Electrolytic Capacitors - Leaded 25volts 100uF 6.3x11mm 105deg - Note: Longer Lead is positive (+).

Solder and trim the leads.

Install DC/DC Converters

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Install three (3) DC/DC Power Converter - 2W 5V 400MA

Solder and trim the leads.

Install Clock Oscillator

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Install One (1) Standard Clock Oscillators 8MHz 3.3V

Solder and trim the leads.

Install RJ45 Connectors

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Install Three (3) Modular Connectors / Ethernet Connectors 8P8C TOP ENTRY

Install Header Pins

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Use the Headers & Wire Housings 36P 1 ROW VERT HDR and seperate into Two (2) 6 pin headers, Two (2) 2 pin headers, One (1) 3 pin header to ISCP1, ISCP2, Test1, Test2 & P3. You will have pins left over.

Install One (1) Headers & Wire Housings BERGSTIKII .100CC DR ST STR to P1

P2 is not used at the moment

Install a Jumper on Test 1.  There is no jumper needed on Test 2

Install USB & Power Connector

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Install One (1) USB Connectors 4P USB R/A RECPT at USB1

Install one (1) DC Power Connectors PCB 2.1MM

Install IC Chips

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Install Six (6) High Speed Optocouplers DIP-8 HS LOGIC GATE In U17, U14, U11, U8, U5 & U2

Note: The Dot and/or Notch is pin 1 of the IC, pin 1 go towards the right as noted on the board silkscreen

Install more IC Chips

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Install Twelve (12) RS-422/RS-485 Interface IC Bus Diff in U18, U16, U15, U13, U12, U10, U9, U7, U6, U4 & U3

Note: The Dot and/or Notch is pin 1 of the IC, pin 1 go towards the right as noted on the board silkscreen

Congratulations you have finished the assembly of your Falcon FPD!

Programming The Falcon FPD

In order to program the Falcon FPD you must use the PICKIT3.

Connect the PICKIT3 to the computer via the USB cable. Plug in the PICKIT3 to to FPD ICSP1 header, making sure triangle mark on the PICKIT3 is at the TOP of the FPD Header.

Start the PICKIT3 programming application. Select "PIC32MX795F512L" from the "Device:" drop down list. Select "File" from the tool bar and select "Import". Navigate to the location of the downloaded firmware and select the Falcon FPD hex file. Click on the write button and once it completes, you may also press the "verify" button. When it has successfully programmed remove the PICKIT3 from ICSP1 and connect to ICSP2 and repeat the programming procedure on the second PIC32.

Congratulations you should now have a functioning Falcon FPD!