HP45 Controller V4.01 PCB assembly

For the guide on assembling the mechanics, click here

For the people that want to assemble their own HP45 controller the following guide is made to help them assemble and test the board. The guide gives a step by step of what components go where. The guide can be used to either solder a board by hand or place the components and reflow. The guide is given as a tool to help assembly with no guarantee for success. The used components have small pitches and might be heat sensitive.

Required tools

To assemble an HP45 controller the following tools are required

  • A temperature controlled soldering iron with a fine tip for SMT work
  • Solder fume extractor
  • Desoldering wick
  • Flux
  • Phillips PH1 screwdriver
  • Isopropylalcohol for cleaning the board

Optionally a reflow oven can be used to solder the board. The exact tools and process then depend on the exact toolchain required for your reflow oven.

Bill of materials

To make a full controller the following components are required. In the remarks some specs can be mentioned if they are important to the function of the controller.

References ValueQty.DescriptionPackageRemarks
C1, C5, C7, C9, C11 1μF5SMD capacitor 0603
C2, C3, C6, C13, C14, C15, C17, C18, C19 0.1μF9SMD capacitor0603
C8 0.1nF1SMD capacitor0603
C4 22μF 1SMD elec. capacitorØ4mmNo taller than 10mm
C10, C12 100μF 2SMD elec. capacitor Ø8mm
C16 1μF 1SMD elec. capacitor Ø4mm
Con1 1HP45 connector HP45 connector
D1, D3, D4, D5, D6 green5LED green0603
D2If 1A+, Vf 0.5V –1Schottky diodeSOD-323HE
F14A, 15V+1Polyfuse through holeThrough hole
F20.5-1A, 15V+1SMD Polyfuse1812
F31-1.5A, 15V+1SMD Polyfuse1812
IC1LMR365101Switching power regulatorSO-PowerPAD-8
IC274HC1231Monostable Multi-vibratorTSSOP-16 4.4x5mm
IC3, IC4TLC592132LED Lighting DriverTSSOP-20 4.4×6.5mm
IC5, IC6, IC9HEF40173Decade counterSSOP-16 4.4×5.2mmVDD 15V
IC7HCF40811And gate ICTSSOP-14 4.4x5mmVDD 15V
IC8LM3111ComparatorSOIC-8 3.9×4.9mm
J15A +13.5mm screw terminal 3xscrew terminal 3.5mm 1×3
J2, J42JST-XH connectorJST-XH 3x straight 2.5mm
J51JST-XH connector JST-XH 5x straight 2.5mm
J61JST-XH connector JST-XH 4x straight 2.5mm
J85A +1DC barrel jackDC barrel jack through hole
L122μH, 1A +1Inductor SMDTaiyo-Yuden 5040
Q1, Q22N-channel MosfetSOT-23
Q378-SIRA12DP-T1-GE31N-channel MosfetSO-8 PowerPAK
R1, R2, R3, R5, R8, R10, R11, R12, R17, R25, R262k2Ω 1% 0.1W11Resistor0603
R4, R16, R19, R22, R24, R2810kΩ 1% 0.1W6Resistor 0603
R6, R7, R9, R14, R15, R18, R21, R271k2Ω 1% 0.1W8Resistor 0603
R13, R2030Ω 1% 0.5W2Resistor 0805
R23, R29, R30330Ω 1% 0.1W3Resistor 0603
uC1Teensy 3.51Micro-controllerTeensy 3.5Requires 2x 24 pin 2.5mm female header
Complete Bill of materials for an HP45 controller V4.01

Part locations and orientation

The parts location are given roughly from small to large, to aid some forms of assembly. This order is not a hard requirement, and as long as all components are placed in the correct spot in the correct orientation, the controller will work.

For some of the smaller components like resistors and capacitors, there will be 2 components in a larger circle. On the IC’s and the large mosfet, the extra circle notifies where pin 1 is. On polarized components the – and sometimes the + is shown.

Resistors

330Ω resistors

There are 3x 330Ω resistors. These are 0603 0.1W 1% accurate resistors. These resistors have no polarity.

The references for the 330Ω resistors are:

  • R23
  • R29
  • R30

1.2kΩ resistors

There are 8x 1.2kΩ resistors. These are 0603 0.1W 1% accurate resistors. These resistors have no polarity.

The references for the 1.2kΩ resistors are:

  • R6
  • R7
  • R9
  • R14
  • R15
  • R18
  • R21
  • R27

2.2kΩ resistors

There are 11x 2.2kΩ resistors. These are 0603 0.1W 1% accurate resistors. These resistors have no polarity.

The references for the 1.2kΩ resistors are:

  • R1
  • R2
  • R3
  • R5
  • R8
  • R10
  • R11
  • R12
  • R17
  • R25
  • R26

10kΩ resistors

There are 6x 10kΩ resistors. These are 0603 0.1W 1% accurate resistors. These resistors have no polarity.

The references for the 1.2kΩ resistors are:

  • R4
  • R16
  • R19
  • R22
  • R24
  • R28

30Ω resistors

There are 2x 30Ω resistors. These are 0805 0.5W 1% accurate resistors. These resistors have no polarity.

The references for the 1.2kΩ resistors are:

  • R13
  • R20

Ceramic capacitor

0.1nF Capacitors

There is 1x 0.1nF capacitor. this is 0603 10% 25V. The capacitor has no polarity.

The reference for the 0.1nF capacitor is:

  • C8

0.1μF Capacitors

There are 9x 0.1μF capacitors. this is 0603 10% 25V. The capacitors have no polarity.

The references for the 0.1μF capacitor are:

  • C2
  • C3
  • C6
  • C13
  • C14
  • C15
  • C17
  • C18
  • C19

1μF Capacitors

There are 5x 1μF capacitors. this is 0603 10% 25V. The capacitors have no polarity.

The references for the 1μF capacitor are:

  • C1
  • C5
  • C7
  • C9
  • C11

Diodes and Leds

Schottky Diode

There is 1x schottky diode. this is SOD-323HA. Forward current needs to be at least 1A. Forward voltage should be 500mV at most. The diode has a polarity. The white painted part is the cathode (-).

The reference for the diode is:

  • D2

Leds

There are 5x Leds. This has a 0603 package. You can use any color. Leds have a polarity. Look in the datasheet of the Led to find the polarity.

The references for the leds are:

  • D1
  • D3
  • D4
  • D5
  • D6

Inductor

Inductor

There is 1x inductor. This has a 5040 package. Inductance needs to be 22μH and at least 1A. The inductor has no polarity.

The reference for the inductor is:

  • L1

Mosfets

Level shift Mosfet

There are 2x mosfets. The package is SOT-23. The type is N-channel. The gate threshold voltage should be lower than 1V. The mosfets should fit only one way.

The reference for the the mosfets are:

  • Q1
  • Q2

Power Mosfet

There is 1x mosfet. The package is SO-8 PowerPAK. Pin 1 is marked by the round mark in the corner or a marked line. Used type is 78-SIRA12DP-T1-GE3

The reference for the mosfet is:

  • Q3

ICs

Power regulator

There is 1x LMR36510 power regulator. The package is SO-PowerPAD-8. Pin 1 is marked by the round mark in the corner or a marked line.

The reference for the IC is:

  • IC1

Monostable multi-vibrator

There is 1x 74HC123. The package is TSSOP-16 4.4x5mm. Pin 1 is marked by the round mark in the corner or a marked line.

The reference for the IC is:

  • IC2

Primitive driver

There are 2x TLC59213. The package is TSSOP-20 4.4×6.5mm. Pin 1 is marked by the round mark in the corner or a marked line.

The references for the IC are:

  • IC3
  • IC4

Address counter

There are 3x HEF4017. The package is SSOP-16 4.4×5.2mm. The chip needs to be 12V minimum. Not all types have the same voltage. The first 3 letters can be different. Pin 1 is marked by the round mark in the corner or a marked line.

The references for the IC are:

  • IC5
  • IC6
  • IC9

AND Gate

There is 1x HCF4081. The package is TSSOP-14 4.4x5mm. The chip needs to be 12V minimum. Not all types have the same voltage. The first 3 letters can be different. Pin 1 is marked by the round mark in the corner or a marked line.

The reference for the IC is:

  • IC7

Comparator

There is 1x LM311. The package is SOIC-8 3.9×4.9mm. Pin 1 is marked by the round mark in the corner or a marked line.

The reference for the IC is:

  • IC8

Electrolytic capacitors

22μF Electrolytic Capacitor

There is 1x 22μF electrolytic capacitor. The capacitance is 22μF. The diameter is 4mm. The minimum voltage is 16V. The capacitor has a polarity. The colored mark is the cathode (-).

The reference for the 22μF capacitor is:

  • C4

100μF Electrolytic Capacitors

There are 2x 100μF electrolytic capacitors. The capacitance is 100μF. The diameter is 8mm. The minimum voltage is 25V. The colored mark is the cathode (-).

The reference for the 100μF capacitor is:

  • C10
  • C12

1μF Electrolytic Capacitors

There is 1x 1μF electrolytic capacitor. The capacitance is 1μF. The diameter is 4mm. The minimum voltage is 25V. The colored mark is the cathode (-).

The reference for the 1μF capacitor is:

  • C16

Fuses

5V Fuse

There is 1x 5V polyfuse fuse. The hold current is 0.5-1A. The maximum voltage needs to be at least 15V. The package is 1812. Fuses have no polarity.

The reference for the 5V fuse is:

  • F2

12V Fuse

There is 1x 12V polyfuse fuse. The hold current is 1-1.5A. The maximum voltage needs to be at least 15V. The package is 1812. Fuses have no polarity.

The reference for the 12V fuse is:

  • F3

VHD Fuse

There is 1x VHD polyfuse fuse. The hold current is 4A. The maximum voltage needs to be at least 15V. The package is radial through hole. Many pitches will fit. Fuses have no polarity.

The reference for the VHD fuse is:

  • F1

Connectors

Power connectors

There are 2x power input connectors. 1x DC barrel jack and 1x 3 pin 3.5mm screw terminal. Both need to handle at least 5A of current. The inputs need to face away from the PCB.

The reference for the power connectors are:

  • J1
  • J8

Serial and I2C connectors

There are 2x data connectors. They are of the JST-XH 2.5mm 3 pin straight type. The openings need to match with the silkscreen.

The reference for connectors are:

  • J2
  • J4

External connectors

There is 1x external connector. This is of the JST-XH 2.5mm 5 pin straight type. The openings need to match with the silkscreen.

The reference for connector is:

  • J5

Encoder connector

There is 1x encoder connector. This is of the JST-XH 2.5mm 4 pin straight type. The openings need to match with the silkscreen.

The reference for connector is:

  • J6

Micro-controller

Teensy 3.5

There is 1x Teensy 3.5. This is a development board with a ARM Cortex-M4. To mount the Teensy you will need 2x 24 pin 2.5mm female header. Optionally you might need matching male headers.

The microcontroller has no reference on the board, only 2 headers.

Assembly

The controller can be assembled in many ways. It is presumed that there is prior SMD experience before assembling this controller. Especially the ICs have fine pitched components and are more difficult to solder.

The easiest soldering order is the one given on the page, going from small to large SMD components. In case the board is reflowed, all the SMD components need to be placed first, then the components need to be reflowed. After that the through hole components can be soldered. When soldering by hand the exact order is slightly less critical.

Testing the controller

Before plugging the controller in, there should be a visual inspection to verify there are no shorts. The first time the controller should be powered by a current limited power supply at 100mA/12V with no microcontroller. If there are any shorts the power supply should limit the current. All 3 power leds should light bright. Now the controller can be inserted and the controller can be powered again with the current limited supply. Only after there are no shorts detected, can the board be powered with 4A 12V.

After flashing the firmware, the controller can test itself. This can be done through the software with the button “Test”. No new warnings should pop up.

For the guide on assembling the mechanics, click here