CirKits SPC3-b1 Solar Power Center Assembly Instructions Dec. 6, 2013 Construction Hints and Tips: ---------------------------- -Parts go on the side of the board with white lettering (silkscreen). -Do not overheat the semiconductors when soldering, especially the LEDs. -Use a clip-on heat sink on semiconductor leads during soldering. -Only use electronic grade 60/40 rosin core solder or equivalent. -Acid core solder will corrode the printed circuit board, don't use it. -Check all of the [] boxes as you assemble your kit. -Diodes have polarity bars that line up with the silk screen on the circuit board. -When working with long leaded parts, bend leads so that the parts fit flush to the board. Insert the leads into the board holes, bend the leads, solder the leads and clip off the excess wire. SPC3 Assembly: -------------- [] Install ZD1, the 1N5242 (242B) zener diode, observe polarity. The 1N5242 zener diode will have a black mark on one of the leads. [] Install the two 1N4004 diodes at D7 and D8, observe polarity. [] Install the five 1N4148 diodes at D2,D3,D4,D5 and D6, observe polarity. [] Install the large 6A05 diode at D1, observe polarity (white band), bend the leads over the silvered area on the bottom of the board. [] Install the 90SQ035 or 90SQ045 schottky diode at SD1, observe polarity, bend the leads over the silvered area on the board. [] Install the 10nF capacitor (marked 103) at C12. [] Install the eleven 100nF capacitors (marked 104) at C1,C2,C3,C4,C5,C6,C7,C8,C9,C10 and C11. [] Install the 470uF electrolytic capacitor at C13, observe polarity. The longer wire on the electrolytic capacitor goes in the hole marked with the + sign. If you are unsure about resistor colors, verify parts with a meter. [] Install the 270 ohm (red violet brown) resistor at R17. [] Install the three 330 ohm (orange orange brown) resistors at R1,R2 and R20. [] Install the four 1K (brown black red) resistors at R3,R18,R19 and R24. [] Install the 2.2K (red red red) resistor at R23. [] Install the 3K (orange black red) resistor at R21. [] Install the 10K (brown black orange) resistors at R5. [] Install the 22K (red red orange) resistor at R4. [] Install the 56K (green blue orange) resistor at R22. [] Install the 75K (violet green orange) resistor at R8. [] Install the four 100K (brown black yellow) resistors at R12,R13, R14 and R15. [] Install the 180K (brown gray yellow) resistor at R9. [] Install the 200K (red black yellow) resistor at R10. [] Install the 270K (red violet yellow) resistor at R6. [] Install the 470K (yellow violet yellow) resistor at R7. [] Install the 1M (brown black green) resistor at R16. [] Install the 3.3M (orange orange green) resistor at R11. [] Install the two 100K potentiometers at RV1 and RV2, the adjustment screws go next to the circuit board edge. [] Install the 2N3904 transistor at Q4, observe board markings. [] Install the two 2N3906 transistors at Q2 and Q5, observe markings. [] Install the two 78L05 voltage regulators at VR1 and VR2, observe board markings. [] Install the 2K thermistor (small black blob with 2 leads) at TM1. [] Bend the leads of the IRLZ44N MOSFET transistors so the leads and mounting holes line up with the circuit board holes at Q1 and Q3. Using the toothpick and the capsule of heat sink grease, spread a thin layer of grease to the metal on the back side of the MOSFETs. Use the 4-40 screws, nuts, and washers to attach the MOSFETs to the board. The transistor leads should be bent to cover the silvered areas on the back side of the board. Solder the leads. [] Solder the 4N35 optical isolator to the board at OC1. OC1 pin 1 is marked with a small circle indentation, that goes near the notch on the part outline. Solder 270K resistor R25 to the bottom of OC1 on pins 4-6, see www.solorb.com/elect/solarcirc/spc3/ for details. [] Solder the TLC2272 dual op-amp to the board at IC1. Pin 1 on the IC is marked with a small circle indentation, that goes near the notch on the part outline. [] Solder the TLC27L4 quad op-amp to the board at IC2. The notch in the IC should line up with the notch on the part outline. The LEDs can be pointed either up or sideways for assembly into a box. If you choose sideways orientation, bend the leads before soldering. [] Solder LED1 to the board, LED1 is translucent white. The flat side of the LED should line up with the board markings. [] Solder LED2 to the board, LED2 is yellow. The flat side of the LED should line up with the board markings. [] Solder LED3 and LED4 to the board, LED3 and LED4 are clear. The flat side of the LEDs should line up with the board markings. [] Insert the fuse into the two fuse clips and solder the fuse assembly to the board at F1. The flat side of the clips should be near the center of the board. [] Insert switch S1 into the board and solder all 5 leads. [] If supplied as two 3-pin connectors, slide the two halves of the 6-pin connector together. Install the connector on the board with the holes toward the edge of the board. [] The two holes marked EQU may be used for connection to an optional user-supplied equalize/overcharge switch, shorting the contacts boosts the float voltage setting for occasional overcharging. [] Verify that C13, the LEDs, the ICs, transistors, and diodes are all oriented correctly. [] Check all of the solder joints for good coverage, use a bright light and a magnifying glass if you can. Retouch any cold solder joints. Check for solder bridges between adjacent pins, remove any bridges. [] Clean the leftover solder flux from the bottom of the circuit board with rubbing alcohol. Use an old tooth brush to scrub the board then soak up the residue with a tissue. Repeat until clean. This completes the board assembly, All parts should now be installed. Should a part be missing, contact cirkits.com for a replacement.