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Construction of a VT Project Box 70










Appendix I
(VT Project Box Construction Manual) 71
Construction of a VT Project Box

Table of Contents

List of Parts for the VT Project Box ...............................................................................73
Construction of the VT84 board.......................................................................................74
VT84 attachment and jumpering......................................................................................77
VT84 wire connections and connectors ...........................................................................78
Attaching screw terminals to the PCBs............................................................................84
Large sub-cover assembly................................................................................................85
VT84 wire connections and connectors from the proto-board.........................................88
Over-voltage protection IC (OVP IC) board construction ...............................................88
Small sub-cover construction and wiring.........................................................................92
Large sub-cover wiring ....................................................................................................99
Large sub-cover connector attachment ..........................................................................104
Input
connector...................................................................................................105
Output
connector ................................................................................................106
Final Assembly...............................................................................................................107
Schematics......................................................................................................................111
Assembly
drawing..............................................................................................111
Box
cover ...........................................................................................................112
Large
sub-cover..................................................................................................115
Small
sub-cover..................................................................................................119
Vertical
panels....................................................................................................122
Mounting
plate ...................................................................................................123
Modified
angle ...................................................................................................125
72
List of Parts for the VT Project Box
Part Description
Supplier
Supplier's Part #
Quantity
VT84 Board Construction Kit
Virginia Tech

1
Sub-mini pushbutton switch (SPST)
Radio Shack
2751571
1
Insulated Stand-offs
Radio Shack
2761381
6
Dual IC protoboard PCB *3
Radio Shack
2760159
1
Experimenters Protoboard PCB *1
Radio Shack
2760170
1
ICB90 Printed Circuit Board (PCB) *2
Radio Shack
2760148
2
2 terminal speaker jack pushbutton
Radio Shack
2740315
1
DPDT slide switch
Radio Shack
2750407
1
8" by 6" by 3" project box
Radio Shack
2701809
1
binding post (female bannana plugs)
Radio Shack
2740661
2 red/2black
BNC Receptacle
Allied Electronics
713-9805
4
DB-9 connector
Allied Electronics
810-6022
1
8-pole screw terminal block
Allied Electronics
502-0508
2
Overvoltage protection IC
Allied Electronics
903-4936
2
4-circuit micro-fit plug
Allied Electronics
863-0503
4
4-circuit micro-fit receptacle
Allied Electronics
863-0525
4
6-circuit micro-fit plug
Allied Electronics
863-0505
2
6-circuit micro-fit receptacle
Allied Electronics
863-0526
2
8-circuit micro-fit plug
Allied Electronics
863-0507
3
8-circuit micro-fit receptacle
Allied Electronics
863-0527
3
male micro-fit terminals
Allied Electronics
863-0536
70
female micro-fit terminals
Allied Electronics
863-0537
70
8-pin IC socket
Allied Electronics
512-4521
2
24 AWG Red wire by the 100 ft **
Allied Electronics
696-9103
~2 ft
24 AWG Black wire by the 100 ft **
Allied Electronics
696-9102
~3 ft
24 AWG Yellow wire by the 100 ft **
Allied Electronics
696-9105
~2 ft
24 AWG blue wire by the 100 ft **
Allied Electronics
696-9106
~20 ft
1/16"X12"X24" Grade XX Garolite Sheet
McMaster-Carr
85315k131
1
1/2"X1/2" 90 degree anlge PVC (5ft sec.)
McMaster-Carr
8659k37
1
1/16"X12"X24" PETG Clear sheet
McMaster-Carr
85815k21
1
1/16"X12"X24" PVC Sheet
McMaster-Carr
8747k123
1
4-40 3/8" Machine scews w/ countersunk
McMaster-Carr
90273A108
8
4-40 nuts with nylon inserts
McMaster-Carr
90631A005
12
4-40 3/8" Machine scews w/ round head
McMaster-Carr
90279A108
4
* These parts can alternatively be purchased



Part Description
Supplier
Supplier's Part #

*1--Experimenters Protoboard PCB
Allied Electronics
910-2197

*2--ICB90 PCB (Dual-mini in Allied's catalog)
Allied Electronics
910-2187

*3 -- Dual IC PCB
Allied Electronics
910-2191





**The wire could be purchased at Radio



Shack in lengths more appropriate







73
Construction

Construction of the VT84 board

One modification made to the VT84 PCB (printed circuit board) is the two holes drilled
into the board. The layout for these holes is shown in Figure 1. The proto-board (Radio
Shack PN: 2760170) needs to be cut to 3.5 by 1.1, after cutting the proto-board, it
should appear as in Figure 2.


Figure 1: Hole pattern for VT84
74

Figure 2: Resized proto-board

Construct the VT84 board using the Mechatronics website
(
http://mechatronics.me.vt.edu/VT84Construction/PICConstruction.html
), omitting the
following steps:

Step 9 Switches

Step 13 20 Pin header

Step 14 DB9 connector

For step 9, solder wires to the solder joints for the switches as shown in Figure 3, noting
there is one solder joint that has no connection on the board and it does not need a wire
attached to it. The wires should be approximately three inches long. For non-ground or
non-power connections such as the switch and the DB-9 connections, it is recommended
to use wire color other than red, yellow, or black.


Figure 3: Wire connections to the switch pads

For step 14, solder wires to the solder joints for the DB-9 connector as shown in Figure 4,
noting there are three solder joints that have no connections and they do not need wires
attached to them. The wires should be approximately three inches long.
75

Figure 4: Wire connections to the DB-9 connector pads

For step 13 the header pins are attached to the VT84 and a proto-board. This is shown in
Figure 5 and Figure 6. It is advised that the short header pins are soldered to the VT84
first. Then, tack the larger header to the VT84 and proto-board. After the alignment of
the header pins are sufficient finish soldering the header to both the proto-board and the
VT84 board. The connections should appear as in Figure 5 and Figure 6.


Figure 5: Solder connections of the header pins to the proto-board
76

Figure 6: Header pin attachment to the proto-board and the VT84 PCB

VT84 attachment and jumpering

Using the schematic in Figure 7, wires approximately 3 long should be soldered to the
corresponding pads on the proto-board. The pads corresponding to pins 11, 12, 13, and
14 are the digital output lines. The pads corresponding to pins 27, 28, 29, and 30 are the
digital input lines. The pads corresponding to pins 21, 22, 23, and 24 are the analog to
digital converter lines. The pads corresponding to pins 1 and 36 are the H-bridge signal
lines. Also, the pad corresponding to pin 32 is the PWM signal that the PIC sends to the
H-bridge. The above pads should have some color of wire attached to them to signify
their function. The pad corresponding to pin 25 should have a red wire (to signify 5v)
attached to it approximately 8 long and another red wire attached to the pad
approximately 3 long. The pad corresponding to pin 26 should have a black wire (to
signify ground) attached to it, that is approximately 8 long. The pad corresponding to
pin 2 should have two 3 long black wires soldered to it. The pad corresponding to pin 3
should have a yellow wire (to signify 12v power) attached to it that is approximately 8
long.

The following pins should be jumpered together using black wire: 2, 26, and 39. The
following pins should be jumpered together us