Extralife Instruments SUPER SIXTEEN User manual

Super Sixteen Build Guide

Guide v1.1 - April, 2021

CPU Board (smaller PCB)

1.1 - Resistors

Install the through-hole resistors by bending the leads and inserting them through the

vias, bending the leads, ﬂipping the PCB, and soldering them. They can go in either way

but it's good to keep all the color codes facing the same way.

1. Install the twelve 1K (1 kiloohm) resistors (brown, black, red,gold)

R103, R104, R105, R106, R107, R108, R109, R110, R111, R112, R113, R116

2. Install the ﬁve 10K resistors (brown, black, orange,gold)

R102, R114, R115, R117, R118

3. Install the one 1M (1 megaohm) resistor (brown, black, black, yellow,brown) (blue body)

R101

Install the resistors in this step in the highlighted locations.

1.2 - Diodes

Install the diodes like the resistors, but be

careful that they are polarized. The stripe

on the diode body must match the stripe on

the PCB silkscreen.

1. Install the two 1N4001 diodes - larger

black plastic diode with silver stripe.

D103, D104

2. Install the two 1N4733A zener diodes -

larger red glass diodes with a black

stripe.

D101, D102

Set aside the BAT85 diode (smaller red

glass diode) - it goes on the other PCB

1.3 - Ceramic capacitors

Install the ceramic caps - they are

non-polarized, so don't worry about

which way is which. Just be careful to

use the right values because they look

similar to one another!

1. Install the four 22 pF capacitors

(code 22J)

C105, C107, C113

and C114 (optional),

2. Install the seven 100nF /0.1uF

capacitors (code 104)

C103, C104, C106,

C111, C112, C115, C116

1.4 - ICs / Chips

First, install the smallest IC - the Winbond

W25Q80DV ﬂash memory chip (U104) in the

corner of the PCB. This is an SOIC-8

surface-mount package. It is the only

surface-mount part in the project. It comes in

a small black plastic tray which is a piece of a

"reel" of chips.

1. "Tin" only one of the IC's pads on the PCB

by applying a small amount of solder to it.

2. Using tweezers, peel oﬀ the clear plastic

protective ﬁlm and remove the IC from the

reel.

3. Locate the "dot" in the corner of the chip indicating which pin is Pin 1. Match this to the dot

on the PCB silkscreen to orient the chip properly. (see photo)

4. Hold the chip with tweezers and place it on the pads in the correct orientation. At the

same time, heat the tinned pad with the soldering iron to "tack" the IC in place. Hold it

down with the tweezers to make sure the IC sits ﬂat against the board while the solder

cools.

5. Apply soldering ﬂux on the legs of the IC and its pads.

6. Apply some solder to the end of the iron, then touch that liquid solder to IC legs and pads

to ﬂow solder into the joints using the pre-applied ﬂux.

7. If solder bridges form between pads, remove them using additional ﬂux and a clean iron

tip, or use solder wick (aka desoldering braid).

Next, install the larger through-hole ICs. Straighten the

legs of each IC by pushing them against a ﬂat surface.

Insert them into the PCB and be careful to install them

in the correct orientation by matching the "divot"

and/or "dot" at one end of the IC with the matching

symbols on the PCB silkscreen. If the chip falls out

when the board is upside-down, bend over the corner

legs with a screwdriver so it stays in place for

soldering.

1. Install the ATMega328P-PU microcontroller,

the large 28-pin IC. (Be careful not to confuse it

with the MCP23S17, another 28-pin chip which

goes on the other PCB)

U103

2. Install the MCP4822 DAC. It is the same size as the next IC,

so be careful to read the labels and get both of them in

the right place.

U106

3. Install the TL072 op-amp.

U105

1.5 - Crystal & Inductors (other)

Install the quartz clock crystal and

inductors. The crystal comes in a metal

can, and the inductors look like large

resistors with a darker color. Neither of

them is polarized.

8. Install the one 16mHz crystal

Y101

9. Install the three 220uH inductors

(red red brown gold)

L101, L102, L103

1.6 - Transistors and Regulators

Install the small TO-92 package transistors by inserting them into the board,

bending the leads out, and soldering them. The ﬂat side of the device must

match the ﬂat side on the PCB silkscreen.

1. Install the four 2N7000 MOSFET transistors

Q101, Q102, Q103, Q104

2. Install the one LP2950-3.3 voltage regulator

U102

On the larger TO-220 package regulator, bend down

each of the leads until they sit at a right angle to its

body. This will allow you to mount it ﬂush against the

PCB.

1. Install the one LM7805 5V voltage regulator

U101

1.7 - Electrolytic capacitors

Electrolytic capacitors are polarized! Install them

by matching the white stripe the white semicircle

on the PCB silkscreen.

1. Install the three 47uF capacitors

C101, C108, C110

2. Install the one 1uF capacitor (C102)

3. Install the one 330uF capacitor (C109)

Note: If you have a very tall 330uF capacitor,

bend its leads ﬁrst so it can lean over and lay

ﬂat against the nearby IC (U105) and hot-glue it

in place. This will let the module ﬁt in smaller

cases.

1.8 - Pin & socket header connectors

The dual-row connectors for power and ICSP, J101

and J104 are installed on the top of the PCB and

soldered on the back, like the other components on

the board. It can be tricky to get them to stay in place.

The easiest way is to use alligator clips, hemostats or

locking tweezers. Alternately, you can mount them

using tape, solder them in place, and remove the

tape. If you have a keyed (aka shrouded) 10-pin

power connector (J104), the key (or notch) should face

toward the lower edge of the PCB.

1. Install the two dual-row header connectors.

J101, J104

The single-row headers connect the 2 PCBs together. They (J102, J103) are installed on the

underside of the PCB and soldered on the top. It's easiest to install them by mating the header

pins to the sockets, and loosely ﬁtting them in both PCBs at once to ensure they go in straight.

Place the Control board in your PCB holder, and loosely install the mated header sockets in their

positions on the backside of that PCB (J1, J2). Then set the CPU board on top and ﬁt the pins

through so both connectors are held in place and parallel. Level both of the boards so the

headers sit straight up and down.

1. Solder the header connectors on the top

side of the CPU board.

J102, J103

Carefully remove the boards from your PCB

holder and ﬂip them over so you can access the

top of the Control board.

2. Solder the header connectors on the top

side of the Control board.

J1, J2

Gently prise the PCBs apart by hand, being

careful not to bend or damage the header pins.

Then take a break! You're halfway there!

Control Board (larger PCB)

NOTE: You should have already soldered the pin headers

on the Control PCB in the previous step!

2.1 - Resistors

Install the through-hole resistors on the Control Board.

1. Install the twelve 100 ohm resistors

(brown, black, brown,gold)

R1, R2, R3, R4, R5, R6, R7, R8, R9, R10,

R11, R12

2. Install the three 680 ohm resistors

(blue,grey,brown,gold)

R14, R15, R16

3. Install the three 1K (1 kiloohm) resistors

(brown, black, red,gold)

R13, R17, R18

4. Install the two 10K resistors

(brown, black, orange,gold)

R19, R22

5. Install the two 100k resistors

(brown, black, yellow, gold)

R20, R23

6. Install the two 1M (1 megaohm) resistors

(brown, black, black, yellow, brown) (blue body)

R21, R24

2.2 - Ceramic Capacitors and Diode

Install the ceramic capacitors and the one remaining diode. Near each IC you'll place a pair of two

ceramic caps, one 100nF and one 100pF. The BAT 85 diode mounts near the bottom of the

board, between the gate output jack and the

potentiometers.

1. Install the three 100 pF capacitors

(code 101)

C3, C6, C9

2. Install the three 100nF /0.1uF capacitors

(code 104)

C2, C5, C8

3. Install the one BAT85 diode (note the

polarity and match the stripe on the diode

to the stripe on the PCB)

D19

2.3 - ICs / Chips

Install the three through-hole ICs. Note that the

orientation of the large MCP23S17 IC is opposite

from the other two ICs. Match each IC so the

notch at one end matches the notch on the PCB

silkscreen.

1. Install the one MCP23S17 I/O expander IC

2. Install the two 74HC595 shift register ICs

U1, U3

2.4 Transistors

NOTE - Updated April 2021

The transistors are easy to install - just bend the leads, and solder as usual. However, please take

note of the orientation of the 2N3906 transistors, which may not match the silkscreen.

On PCBs labeled version 2.2 and earlier, the

silkscreen orientation is reversed. While the

seven-segment display will still work with

reversed transistors, it will be much less bright.

On all versions of the PCB, the 2N3906

transistors should be installed with the ﬂat side

facing *away* from the top edge of the PCB. This

will greatly increase the display brightness (and

also the electric current usage of the module -

adding roughly 60mA at peak).

The 2N3906 transistors in the photo above are installed in the

correct orientation on a v2.2 PCB with incorrect silkscreen.

1. Install the three 2N9306 transistors next

to the display, with the ﬂat side facing

away from the top edge of the PCB.

Q1, Q2, Q3

2. Install the two 2N3904 transistors next to

the large IC, orienting them as marked on

the silkscreen.

Q4, Q5

2.5 - Tactile Switches

Next you can install all twenty-one 6mm tact switches.

It's very important that they all sit ﬂat against the PCB

so that the button caps line up properly with the front

panel. Push them down and they should "click" against

the PCB as the "gull-wing" bent leads should hold them

ﬁrmly in place. The leads can sometimes be bent during

transit so don't force them too hard, and bend the leads

gently back into position if necessary.

This step requires making 84 individual solder joints!

Take it slow and take a break in the middle.

1. Install the twenty-one tactile switches

S1, S2, S3 … S21

2.6 - Potentiometers, Encoder, Hex Standoﬀ

At last, it's time to install the through-panel components! The potentiometers and encoder should

be installed into the PCB, and then aligned using the front panel before and during soldering.

Otherwise it is possible to misalign the pots, and it will be very diﬃcult to ﬁx!

Before ﬁtting the front panel, install the 10mm hex standoﬀ via an M3 screw in the hole just below

the encoder (see diagram). This will keep the panel at the proper height and angle.

1. Install the hex standoﬀ near the encoder (SW3)

2. Press-ﬁt the encoder and potentiometers into

place. You may have to bend the mounting tabs

inward slightly.

3. Install the front panel, clamp it in your PCB

holder and ﬂip the assembly over. If you don't

have a PCB holder, install the hex nuts on the

potentiometers and the M3 screw into the hex

standoﬀ to hold the panel in place during

soldering. Do not put a hex nut on the encoder.

4. Solder the 3 control pins of each potentiometer

and the rotary encoder.

SW3, RV1, RV2, RV3, RV4

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