D O T K L O K Assembly Instructions

28 October 2011
www.aomalley.org/dotklok / www.andrewomalley.etsy.com
Required tools / materials
soldering iron
solder
wire strippers
flush cutters / wire nippers / diagonal cutters
multi-bit screwdriver
small / needle-nose pliers
Optional tools / materials
helping hands
solder fan / defumer
multi-meter
solder sucker/vacuum
solder wick
lint-free / microfiber cloth
ART I! "# A$$%&#L'

Your final PCB will look like this, once fully assembled
1
All parts sit on the top of the board and are soldered from the bottom.
Please refer to the bill of materials (B!"#
www.aomalley.org/dotklok/files/$%&'&(bom(illustrated.pdf
for an illustrated parts list.
%ake care when unpacking the kit components) there are several small
parts) and no e*tras have been provided. TI! the foam housing for the
'+$ screen makes for a handy parts tray while assembling $%&'&.
,f your P-B is labeled .$%&'& 1.1/ you will need to solder a wire
across the 0P1 pads in order for the board to work with the power
supply included with your kit. Although a specific wire has not been
included for soldering this 1umper) you can can use one of the cut-off
leads from a resistor or capacitor soldered in the following steps.
2
Solder a wire
across JP1
1. 3older 4$51 (si* pin) right-angle header) no polarity") with long pins
facing out from P-B.
2. 3older 3&2 (small) 6 pin chip holder" at ,-2 and 3&1 (large) 26 pin
chip holder" at ,-1) matching the notch of the chip holder with the
notch on the P-B diagram.
7
Note, notches
(circled) must
match by facin
left
Note, lon !ins
facin out from
PCB
7. 3older 81 (19!h: crystal) no polarity") -1 and -2 (22p; capacitors)
no polarity) marked 22<". ,f needed) bend leads to hold components
in board during soldering= once soldered) trim e*cess leads from
back of P-B.
>
S"# (small $ !in
chi! holder) at
%C#& Note, notch
(dotted circle)
faces left
Bent leads
best hold
com!onents in
while
solderin'
()cess leads
should then be
trimmed
S"1 (lare #$
!in chi! holder)
at %C1& Note,
notch (dotted
circle) faces left
4. 3older 57 (1<k resistor) no polarity) colour bands# brown-black-
orange" and -? (<.1u; capacitor with long leads) no polarity) marked
1<>") trim e*cess leads from back of P-B.
?
*1 (1+,h-
crystal) with C1
and C# (##!.
ca!acitors)
/0 (11k
resistor) and C2
(1&1 u.
ca!acitor)
5. 3older 51 and 52 (1k resistors) no polarity) colour bands# brown-
black-red" and -7 (<.1u; capacitor with long leads) no polarity") trim
e*cess leads from back of P-B.
6. 3older 5> and 5? (2.2k resistors) no polarity) colour bands# red-red-
red") trim e*cess leads from back of P-B.
9
/1 and /# (1k
resistors) and
C0 (1&1 u.
ca!acitor)
/3 and /2 (#&#k
resistors)
@. 3older -5122< (coin cell holder". Aote) coin cell holder must be
placed so that the sBuare edge points left.
8. 3older C1 (1< position screw connector". penings &($T face
outer edge of P-B.
@
C/1##1 (coin
cell holder)&
Note, s4uare
ede !oints left
51 (11 !osition
screw connector)
o!enin ,6S7
be !laced so
o!en !art faces
outer ede of
PCB as shown in
the red circle&
7he connector
should N87 be
!laced with the
closed end facin
the outer ede
(as shown in the
crossed out
!icture)
FAIL
9. 3older -> (1<u; polari)ed capacitor") making sure (longer"
positive lead (black side of cap" goes into sBuare (left" pad. (Aote#
the negative side of the cap is marked with a silver/grey stripe"= trim
e*cess leads from back of P-B.
6
51 (11 !osition
screw connector)&
Note, o!en !art
faces outer ede
of PCB
C3 (11u.
ca!acitor) is
!olari-ed& 9oner
(!ositi:e) lead is
marked by the
black side'
shorter (neati:e)
lead is marked by
the rey side
1<. 3older 4$52 (two separate 6-pin upright headers" 3hort leads !D3% go
into the board for soldering= taller leads !D3% face upright) coming up
from top of board. +nsure headers are soldered so they are straight and
upright. Eou do not want them to be crooked.
F
C3 (11u.
ca!acitor) loner
(!ositi:e) lead
(marked by the
black side) ,6S7
o into the
s4uare (left) !ad
on the board
Short leads
,6S7 o into the
board for
solderin
11. 3older 82 (72.@96k4: crystal) no polarity". ,mportant) push the
crystal A'E half way down into the board. 3older and trim e*cess
leads from back of P-B. %hen) gently bend crystal down against
P-B to match diagram on P-B.
1<
;s best as
!ossible, ensure
headers are
soldered so they
are straiht and
u!riht& You do
not want them to
be crooked
Push the *#
(0#&<+$ k=-
crystal) 8N9Y >
down into the
board so that half
of the leads can
be seen from the
to! of the board
12. 3older -A1 (power 1ack". ,nsert so that 1ack is facing outward from
board. Ghen inserting the component into P-B) the back and side
leads can be bent to better hold it in the board. 3older the leads to
the edge of the circular holes. ,t is not necessary to fill in the entire
hole.
11
8nce the crystal
is soldered in the
board, bend the
crystal down
aainst the PCB,
so it co:ers the
diaram on the
PCB
Place CN1
(!ower ?ack) into
three round holes
on PCB (note
these holes are
not labeled on
board)& Sil:er
!ower ?ack must
face out from
board
12
Solder the leads
to the ede of the
circular holes'
note, the solder
does not need to
fill the hole, a
decent solder
connection ?ust
needs to be
made
Note how
o!enin is facin
out from board
-ongratulationsH EouIve now completed the soldering of your P-B. Eour
final soldered board should look like this#
ART II! I*$%RTI*+ T,% ",I$
1. ,nsert ,-1 (A%mega726" into ,-1 chip holder. %nsure notch on chip
lines up with notch on chip holder. !ake sure all pins are aligned. Aote)
chip pins may need to be slightly bent with pliers to ease insertion. %hen)
gently press into place.
17
Note, these
breakout !ins
ha:e intentionally
been left em!ty
so you can use
your creati:ity to
add sensors,
e)tra buttons,
bu--ers, etc& to
your @87"98"
Note, notch on
chi!
2. ,nsert ,-2 ($317<@" into ,-2 chip holder. %nsure notch on chip lines up
with notch on chip holder. !ake sure all pins are aligned. Aote) chip pins
may need to be slightly bent with pliers to ease insertion. Jently press chip
into place.
1>
Notch on chi!
must alin with
notch on chi!
holder& ,ake
sure all !ins are
alined before
ently !ressin
the chi! into
!lace
Note, notch on
chi!
7. ,nsert coin cell into coin cell holder (-5122<") by slipping under metal
tab. %he .K/ side must face upward when placed into coin cell holder.
1?
Notch on chi!
must alin with
notch on chi!
holder& ,ake
sure all !ins are
alined before
ently !ressin
the !in into !lace
Note, inserted
coin cell sli!s
under metal tab
with the ABC side
of the cell facin
u!ward
Note, writin or
ABC side of coin
cell must face
u!ward when
!laced in coin cell
holder
ART III! T%$TI*+ T,% "# A*D $"R%%*
Eou are probably an*ious to test your newly populated P-BH 4owever)
before powering everything up for the first time) it is wise to do a visual
inspection of the bottom of the circuit board.
III.1 Checking soldering
3tart by looking for solder bridges -- places where e*cess solder might
bridge between ad1acent connections) making unwanted electrical
connections.
,f you find any solder bridges) they are easily removed with the soldering
iron) though sometimes a solderer sucker/vacuum or solder wick may be
needed to remove larger amounts of e*cess solder.
,f you have a multi-meter) now would be a good time to ensure there isnIt a
short between power (?L" and ground (JA$".
Eou can test for continuity (or resistance" across the ?L and JA$ pads of
the prototyping area= ideally) you want to find no continuity or a very high
resistance (appro*. 27< &hm".
,f you do find a short circuit) you will need to hunt for and remove this short
before proceeding= otherwise you will damage the board) the screen)
and/or the power supply.
19
7est for continuity
(or resistance)
across the 2D
and EN@ !ads of
the !rototy!in
area
III.2A Testing the Board & Screen screens with chips on FROT
T-e .ollo/in0 steps are .or t-e ori0inal $ure screens /-ic-
-a1e t-e c-ips and selector s/itc- on t-e same side o. t-e
board as t-e L%Ds2 3T-e steps .or t-e ne/ $ure screens are
in section III.2B4

A4 Gith the screen facing right side up) so the '+$s are showing) ensure
-31) (pin 1 of 3G1" on the screen is flipped to the right/on position and
pins 2) 7) and > are all flush left.
1@
(nsure CS1, !in
1 of SF1, on the
screen is fli!!ed
to the rihtGon
!osition and !ins
#,0,3 are all flush
left
#4 Aow) flip the screen over) face down) so you see the solder connections
and electrical sockets.
"4 %o attach the ribbon cable to the screen) place the ribbon cable so the
connector pins are facing downward and the red side of ribbon cable is at
the top. %hen) insert the notched connector into the left socket (B52" of the
screen.
16
Screen !laced
face down so
solder
connections and
electrical sockets
show
Connector !ins
must face
downward with
the red side of
ribbon cable at
the to!& 7he
notched
connector oes
into the left
socket (B/#) of
the screen
D4 Gith the P-B placed to the right side of the screen) connect the other
side of the ribbon cable to 45$2 on the P-B) ensuring the bump on the
ribbon cable connector aligns with the 45$2 label on the P-B. +nsure all
the connector wholes are properly aligned with all the connector pins. %he
red side of the ribbon cable should be closest to the prototyping area.
%4 EouIre now ready to power the screen up for testingH Although the
buttons are not yet attached for setting the time or switching the
animations) once you plug the power supply into the board and plug the
supply into the wall) the display should show a simple time animation with
hours and minutes. %he $%&'& may take a few seconds to start up)
this is normal. A note about the power supply# only use a ?L supply as
included with your kit) input voltages greater than ?L G,'' $A!AJ+ the
boardH
1F
7he red side of
ribbon cable at
the to!&
7he notched
connector oes
into the left
socket (B/#) of
the screen
Connect the
other side of the
ribbon cable to
=/@# on the
PCB, ensurin
the bum! on the
ribbon cable
connector alins
with the =/@#
label on the PCB
54 nce youIve ensured your screen works properly) you can unhook the
power supply and remove the ribbon cable from the P-B. Eou should then
use the white :ip tie to bundle one loop of e*cess ribbon cable.
2<
Plu the !ower
su!!ly into the
board and !lu
the su!!ly into
the wall
7he dis!lay will
show a sim!le
time animation
with hours and
minutes
III.2B Testing the Board & Screen screens with chips on BAC!
T-e .ollo/in0 steps are .or t-e current $ure screens /-ic-
-a1e t-e c-ips and selector s/itc- on t-e opposite side o.
t-e board as t-e L%Ds2
A4 Gith the screen facing down) so the '+$s are not showing) ensure
-31) (pin 1 of 3G1" on the screen is flipped to the up/on position and pins
2) 7) and > are all flush down.
21
Bundle one loo!
of e)cess ribbon
cable with the -i!
tie !ro:ided
(nsure CS1, !in
1 of SF1, on the
screen is fli!!ed
to the u!Gon
!osition and !ins
#,0,3 are all flush
down&
#4 Gith the screen still flipped over) face down) connect the ribbon cable to
the left connector (B52") so that it e*tends leftward of the screen) and the
red edge of the cable faces up/forward.
"4 %o attach the ribbon cable to the screen) place the P-B to the left of the
screen) and connect the free connector to 4$52) ensuring that the bump
on the connector aligns with the 4$52 te*t on the P-B. Also make sure
all the connector holes align with the header pins. %he red edge of the
ribbon cable should be closest to the prototyping area of the P-B.
22
Cable connected
to B/#
Cable e)tends to
left, and red ede
is at to!Gfront
Cable connected
to =@/# such
that bum! on
connector is
alined with
=@/# label on
PCB
D4 EouIre now ready to power the screen up for testingH Although the
buttons are not yet attached for setting the time or switching the
animations) once you plug the power supply into the board and plug the
supply into the wall) the display should show a simple time animation with
hours and minutes. %he &'& may take a few seconds to start up) this is
normal. A note about the power supply# only use a ?L supply as included
with your kit) input voltages greater than ?L G,'' $A!AJ+ the boardH
%4 nce youIve ensured your screen works properly) you can unhook the
power supply and remove the ribbon cable from the P-B.
27
Plu the !ower
su!!ly into the
board and !lu
the su!!ly into
the wall
7he dis!lay will
show a sim!le
time animation
with hours and
minutes&
54 Before proceeding with the assembly) you will need to notch out the top
holes of the screen. %his is done carefully with sharp wire nippers or a
small saw. $ue to a manufacturing discrepancy) this only needs to be
done w/ the new 3ure screens which have the chips on the back of the
panel (opposite the '+$ side".
2>
ANotchC the to!
two holes of
the dis!lay,
usin shar!
wire ni!!ers or
a small saw&
ART I6! #(TTO* R%ARATIO*
1. Dsing the wire cutters) cut two 6/ lengths of wire) two @/ lengths of
wire) and one 7/ length. Ae*t) split the end of each into two halves.
+ach half should be about a centimeter (1/2/" long. %hen) strip a few
millimeters (1/6/" of insulation from the ends of each wire.
2. %in the split ends of each wire (by applying a small amount of solder
to each split end"= while optional) this will aid with assembly in later
steps.
7. ,nsert the split ends of each 6/ wire in the two holes located on the
metal prongs of a button (B1-B>) no polarity"= solder the wire to the
button. 5epeat for the two @/ wires. %rim the e*cess wire.
2?
S!lit the ends of
each of the wires
into two hal:es&
7hen, stri! a bit
of insulation from
the wire ends
7in the s!lit ends
of each wire (by
a!!lyin a small
amount of solder
>. 3older the 7/ wire to the sliding switch (B?" so that the wire is placed
in the first two wholes on top the left. Aote) the top is marked by the
-3A logo.
29
%nsert the s!lit
ends of the wire
into the holes on
the button' solder
the connection
Solder the 0C wire
so the wire is
!laced in the first
two wholes on
to! the left& Note,
the to! is marked
by the CS; loo
ART 6! A$$%&#LI*+ T,% KLOK
.or this section, !lease refer to these @87"98" !anel diarams for hole
identificationH
2@
1. 5emove any protective sheets from the front and back acrylic panels.
2. ,nsert each M inch screw (!37" through the te*t-side of the back panel
into the holes labeled .-/. %he screw head should be face up on the te*t
side of the back panel.
7. ;lip the back panel over (so te*t is not showing". Place N spacers (32"
onto each screw.
>. Place the P-B on top of the spacers (so that 4$51 on the P-B points
to the top O away from the sBuare slot at the bottom-left". %hen) secure
each screw with a >->< nut (A1". %ighten snuggly) without over-tightening.
26
%nsert each I
inch screw (,S0)
throuh the to! of
the back !anel
(te)t side
showin) into the
holes labeled AC'
the screw head
should be face u!
.li! the back
!anel o:er (so
te)t is not
showin)' !lace
J s!acers (S#)
onto each screw
?. ;lip the back panel over so the te*t-side is showing) then place each N
inch screw (!31" into the holes labeled .+/ near the rectangular slot.
9. ;lip the back panel over (so no te*t is showing". Place B? (sliding
switch" onto the screws. %he switch should be placed so the pins are
showing and the wire is at the top right corner. %hen) flip the panel back
over and secure each screw with a 2-?9 nut (A2". %ighten snuggly) without
over-tightening
2F
Note, =@/1 on
the PCB !oints to
the to!
Note, B2 (slidin
switch) should be
!laced so !ins
are showin and
the wire is at the
to! riht corner
@. %ake the switch wires (no polarity" and insert one the wire into the first
(top / closest to the -5122< battery" slot and the second wire into the
second (ne*t closest to top" slot of the green screw terminal connector
(C1". %ighten the connector screws with a screw driver) and make sure the
wires are secured in the connector.
6. ;ind the two buttons with 6/ wires and remove the black plastic nut from
each button.
7<
%nsert one side of
the s!lit wire into
the first (to!) slot
and the second
wire into the
second (ne)t
closest to to!)
slot of the reen
screw terminal
connector
/emo:e the
black !lastic nut
from each button
by unscrewin it
F. ;rom the test side of the front panel (marked with $%&'& te*t") insert
each button with the 6/ wire into the right-side holes labeled .B/. %hen) flip
the panel over to the backside (so you no longer see the te*t" and secure
the buttons with the black) plastic nut by placing the serrated edge of the
nut against the acrylic panel. 4and tightening is sufficient.
1<. ;ind the two buttons with @/ wires and repeat steps P6 and PF) by
removing move the black plastic nut from each button) inserting each
button into the '+;% holes labeled .B/) then) securing the buttons with the
black) plastic nut by placing the serrated edge of the nut against the acrylic
panel.
11. Arrange the top and bottom panels so they are placed beside each
other. 3uch that the top of each panel faces out= the buttons with the
longer (6/" wires are at the top of the photo below#
71
%nsert each
button (from the
front of the !anel)
into the rihtKside
holes labeled ABC
then secure the
buttons by reK
fastenin the
black !lastic nut
Place the !anels
beside each
other& so the to!
of each !anel
faces out, as
shown
12. -onnect the B2 wires (no polarity" to the ne*t two openings (closest to
the left) right beside the B? connections" in the green screw terminal
connector (C1". %ighten the connector screws with a screw driver and
make sure the wires are secure.
17. -onnect the B1 wires (no polarity" to the ne*t two openings (left-most)
beside the B2 wires" in the green screw terminal connector (C1". %ighten
the connector screws with a screw driver and ensure the wires are secure.
72
Connect the B#
wires to the leftK
most o!enins in
the reen screw
terminal
connector
Connect the B1
wires to the ne)t
leftKmost
o!enins in the
reen screw
terminal
connector
1>. Pass the wire from B> under the P-B. -onnect the B> wires (no
polarity" to the ne*t two openings (left-most" in the green screw terminal
connector (C1". %ighten the connector screws with a screw driver and
ensure the wires are secure.

1?. Pass the wire from B7 under the P-B. -onnect the B7 wires (no
polarity" to the last two (right-most" openings in the green screw terminal
connector (C1". %ighten the connector screws with a screw driver and
ensure the wires are secure.
19. Aow is a good time to take a lint-free cloth and remove any unwanted
finger prints or dust.
77
Connect the B3
wires to the ne)t
leftKmost
o!enins in the
reen screw
terminal
connector' note
how wire is
routed under the
PCB
Connect the B0
wires to the
closest bottom
o!enins in the
reen screw
terminal
connector' note
how wire is
routed under the
PCB
1@. Place each 1.?/ screw (!3>" into the back panel (te*t-side showing"
holes labeled .$/. %hen) on the non-te*t / component side of the back
panel) place each 1/ spacer (37" on to each screw) followed by each
<.12?/ (3>" spacer.
16A. 5or ori0inal $ure screens 3c-ips/s/itc- on L%D side4 and
lon0 ribbon cable! 'ocate the screen with the connected ribbon cable.
-onnect the loose end of the ribbon cable to the P-B) ensuring the bump
on the black connector is aligned with the 4$52 te*t on the P-B. ,n this
orientation) the red edge of the ribbon cable will be closest to the
prototyping area.
7>
Place each 1&2C
screw into the
holes labeled L@C,
then !lace each
1C s!acer,
followed by each
1&1#2 s!acer
onto each screw
Connect the
loose end of the
ribbon cable to
the PCB,
ensurin the
bum! on the
black connector
is alined with
the =@/# te)t on
the PCB& Note,
the red ede of
the ribbon cable
should be closest
to the !rototy!in
area
16B. 5or current $ure screens 3c-ips/s/itc- on bac7 side4
and s-ort ribbon cable! 'ocate the screen with the connected ribbon
cable. -onnect the loose end of the ribbon cable to the P-B) ensuring the
bump on the black connector is aligned with the 4$52 te*t on the P-B. ,n
this orientation) the red edge of the ribbon cable will be closest to the
prototyping area.
1F. Place the screen on top of the .$/ spacers and screws) ensuring the
button wires are routed through the sides (as opposed to the bottom" of the
screen. 5oute/place the ribbon cable such that it does not block the power
1ack (-A1".
7?
Place the screen
on to! of the
s!acers' note,
the wires are
routed throuh
the sides (not
bottom) of the
screen
Connect the
loose end of the
ribbon cable to
the PCB,
ensurin the
bum! on the
black connector
is alined with
the =@/# te)t on
the PCB& Note,
the red ede of
the ribbon cable
should be closest
to the !rototy!in
area
2<. 3ecure each screw with the >->< (A1" bolts. Aote) the ribbon cable
may push the screen up a bit while positioning. %his is normal. 0ust press
the screen down gently) yet firmly.
21. Place the silver 7/6/ screws (!32" through the back panel (te*t-side
showing" holes labeled .A/. %hen (on the no te*t / component side of the
back panel" attach each 2/ (31" standoff.
79
Secure each
screw with the
3K31 nuts
Place the sil:er
0G$C screws
(,S#) into the
back !anel holes
labeled A;C
then attach each
#C standoff
22. Align the top panel ($%&'& te*t showing" with standoffs. Place the
black 7-6/ screws (!3?" through the front panel ($%&'& te*t showing"
holes labeled .A/.
27. %ighten the front and back screws (in the holes labeled .A/" with a
screwdriver. %hen) tighten the nuts that hold the screen on.
7@
Place the black
0G$C screws into
the front !anel
holes labeled A;C
7ihten the nuts
and screws
29. ,nsert the power 1ack into the connector located on the bottom of the
P-B to the left of the ribbon cable. %hen) tuck away any e*cess wire from
the buttons under the P-B so everything appears neat and tidy.
2@. Plug in the power supply and en1oy the fruits of your laborH
"on0ratulations on assemblin0 your DOTKLOK88
$-o/ o.. a p-oto o. your ne/ly assembled DOTKLOK at!
///2.aceboo72com/dot7lo7
$upport is a1ailable at t-e DOTKLOK .orum!
///2tec-noetc2net/dot7lo7/.orum
T-an7s a0ain .or your DOTKLOK purc-ase9
%tsy .eedbac7 /ould be 0reatly appreciated2
Andre/ O:&alley
///2aomalley2or0
76
%nsert the !ower
?ack to the
connector located
on the bottom of
the PCB to the
left side of the
ribbon cable,
then tuck away
any e)cess wire