Drone_Build_Diagramsv4.pdf

8/9/2019 Drone_Build_Diagramsv4.pdf

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Casper ElectronicsVersion 1.0Updated December 3rd, 2009


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These diagrams will serve as a step-by-step document to aid in the

assembly of your Drone Lab!

To start off, you are going to be needing a number of materials and tools:

- Soldering Iron

A cheap radio shack unit will technically work, but a nicer temperaturecontrollable iron will save time and frustration.

- SolderWhatever type you prefer, small gauge solder helps avoid excessively large

joints.

- Wire Cutters

The type with the flat cutting edge for nipping leads off close to the board.- Needle Nose Pliers- Flathead Screwdriver- Solder Wick

Extremely helpful when removing shorts / de-soldering joints.

- Multi-Meter

Extremely helpful in debugging. Get one that beeps when it detects electricalcontinuity, and learn how to use all the functions!


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Here’s the parts that are required to build a functional Drone Lab. They are all included in the

kit. In the following pages you’ll see pictures of each component. If you purchased a kit,

please make sure you have all of the components shown. There was great effort paid tomaking sure all of the kits went out complete, but if indeed a mistake was made contact us

directly. Note, if you received an enclosure, you should have received a hardware bag that

includes nylon standoffs.

Resistors Capacitors Switches Jacks + Power

100 1 10pF 2 Slide DPDT 10 1/8" Mono w/ Switch 3

470 1 1000pF 1 Total 10 5.5mm DC w/ Switch 1

1k 5 2200pF 2 1/4" Mono 2

2.2k 8 4700pF 3 Potentiometers 9V 1

10k 14 .022uF 4 10k 4 PC Mount Bat Box 1

22k 6 .1uF 16 50k 12 Total 8

51k 2 1uF 1 1M 9

56k 1 2.2uF 4 Total 25 ICs + Sockets

100k 18 10uF 10 14 Pin DIP Sockets 4

330k 4 100uF 3 Diodes TLC556 2

470k 1 220uF 1 Red LED 6 CD 40106 1

1M 4 Total 47 8.2V Zener 1 TL074 1

4.7M 2 4148 1 Total 9

Total 67 Transistors 1N4001 1

2N3904 7 Total 9

2N3906 8Total 15


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Values of component numbers, helpful if you’re building off the board silkscreen.

Resistors Capacitors Potentiometers Diodes Jacks + Battery

R49 100 R52 51k C39 10pF C3 10uF BPF_F1 10k D1 Red LED C_IN 1/8" Mono w/ Switch

R54 470 R 53 51k C40 10pF C4 1 0uF BPF_F2 10k D2 Red LED C_OUT 1/8" Mono w/ Switch

R4 1k R6 56k C33 .001uF C5 10uF DIST_AMNT 10k D3 R ed LED C_THRU 1/8" Mono w/ Switch

R39 1k R2 100k C26 2200pF C6 1 0uF LPF_CUT 10k D4 Red LED DC_JACK 5mm w/ Switch

R41 1 k R3 1 00k C32 2200pF C25 10uF BPF_BAL 50k D5 Red LED INPUT 1/4" Mono

R51 1 k R5 100k C24 4700pF C27 10uF DIST_VOL 50k D6 Red LED OUTPUT 1/4" Mono

R56 1k R 22 100k C30 4700pF C28 10uF FPITCH1 50K D7 9V Zener Battery 8.2V

R1 2.2k R23 100k C31 4700pF C34 10uF FPITCH2 50K D8 4148 Battery Box PC Mount

R8 2.2k R24 100k C8 .022uF C38 10uF FPITCH3 50K D9 1N4001

R9 2.2k R25 100k C9 .022uF C42 10uF FPITCH4 50K Switches

R16 2.2k R34 100k C10 .022uF C2 100uF IN_VOL 50k Transistors SW1 POWER

R21 2.2k R35 100k C11 .022uF C29 100uF MASTER_VOL 50k Q1 2N3904 SW2 INVERT1

R29 2.2k R36 100k C12 .1uF C43 100uF VOL1 50k Q2 2N3906 SW3 T_OFF1

R33 2.2k R37 100k C14 .1uF C1 220uF VOL2 50k Q3 2N3904 SW4 INVERT2

R47 2.2K R38 100k C17 .1uF VOL3 50k Q4 2N3906 SW5 T_OFF2

R7 10k R40 100k C19 .1uF VOL4 50k Q5 2N3906 SW6 INVERT3

R14 10k R46 100k C20 .1uF CPITCH1 1M Q6 2N3904 SW7 T_OFF3

R15 10k R59 100k C21 .1uF CPITCH2 1M Q7 2N3906 SW8 INVERT4R18 10k R60 100k C22 .1uF CPITCH3 1M Q8 2N3906 SW9 T_OFF4

R20 10k R61 100k C23 .1uF CPITCH4 1M Q9 2N3904 SW10 TREM OFF

R26 10k R62 100k C35 .1uF DIV1 1M Q10 2N3906

R27 10k R17 330k C36 .1uF DIV2 1M Q11 2N3906 ICs & Sockets

R28 10k R19 330k C37 .1uF DIV3 1M Q12 2N3904 U1 LM7809

R32 10k R30 330k C41 .1uF DIV4 1M Q13 2N3906 U2 CD 40106

R43 10k R31 330k C44 .1uF RATE 1M Q14 2N3904 U3 TLC556

R48 10K R42 470k C 45 .1uF Q15 2N3904 U4 TLC557

R57 10k R64 1M C46 .1uF U5 TL074

R58 10K R65 1M C47 .1uF Sockets 14 Pin DIP x 4

R63 10K R66 1M C7 1uF

R10 22k R67 1M C13 2 .2uF

R11 2 2k R50 4 .7M C15 2.2uF

R12 2 2k R55 4 .7M C16 2.2uFR13 22k C18 2.2uF

R44 22k

R45 22K


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Which component is which value.

Resistors Capacitors Potentiometers Diodes Jacks + Battery

R49 100 R52 51k C39 10pF C3 10uF BPF_F1 10k D1 Red LED C_IN 1/8" Mono w/ Switch

R54 470 R 53 51k C40 10pF C4 1 0uF BPF_F2 10k D2 Red LED C_OUT 1/8" Mono w/ Switch

R4 1k R6 56k C33 .001uF C5 10uF DIST_AMNT 10k D3 R ed LED C_THRU 1/8" Mono w/ Switch

R39 1k R2 100k C26 2200pF C6 1 0uF LPF_CUT 10k D4 Red LED DC_JACK 5mm w/ Switch

R41 1 k R3 1 00k C32 2200pF C25 10uF BPF_BAL 50k D5 Red LED INPUT 1/4" Mono

R51 1 k R5 100k C24 4700pF C27 10uF DIST_VOL 50k D6 Red LED OUTPUT 1/4" Mono

R56 1k R 22 100k C30 4700pF C28 10uF FPITCH1 50K D7 9V Zener Battery 8.2V

R1 2.2k R23 100k C31 4700pF C34 10uF FPITCH2 50K D8 4148 Battery Box PC Mount

R8 2.2k R24 100k C8 .022uF C38 10uF FPITCH3 50K D9 1N4001

R9 2.2k R25 100k C9 .022uF C42 10uF FPITCH4 50K Switches

R16 2.2k R34 100k C10 .022uF C2 100uF IN_VOL 50k Transistors SW1 POWER

R21 2.2k R35 100k C11 .022uF C29 100uF MASTER_VOL 50k Q1 2N3904 SW2 INVERT1

R29 2.2k R36 100k C12 .1uF C43 100uF VOL1 50k Q2 2N3906 SW3 T_OFF1

R33 2.2k R37 100k C14 .1uF C1 220uF VOL2 50k Q3 2N3904 SW4 INVERT2

R47 2.2K R38 100k C17 .1uF VOL3 50k Q4 2N3906 SW5 T_OFF2

R7 10k R40 100k C19 .1uF VOL4 50k Q5 2N3906 SW6 INVERT3

R14 10k R46 100k C20 .1uF CPITCH1 1M Q6 2N3904 SW7 T_OFF3

R15 10k R59 100k C21 .1uF CPITCH2 1M Q7 2N3906 SW8 INVERT4R18 10k R60 100k C22 .1uF CPITCH3 1M Q8 2N3906 SW9 T_OFF4

R20 10k R61 100k C23 .1uF CPITCH4 1M Q9 2N3904 SW10 TREM OFF

R26 10k R62 100k C35 .1uF DIV1 1M Q10 2N3906

R27 10k R17 330k C36 .1uF DIV2 1M Q11 2N3906 ICs & Sockets

R28 10k R19 330k C37 .1uF DIV3 1M Q12 2N3904 U1 LM7809

R32 10k R30 330k C41 .1uF DIV4 1M Q13 2N3906 U2 CD 40106

R43 10k R31 330k C44 .1uF RATE 1M Q14 2N3904 U3 TLC556

R48 10K R42 470k C 45 .1uF Q15 2N3904 U4 TLC557

R57 10k R64 1M C46 .1uF U5 TL074

R58 10K R65 1M C47 .1uF Sockets 14 Pin DIP x 4

R63 10K R66 1M C7 1uF

R10 22k R67 1M C13 2 .2uF

R11 2 2k R50 4 .7M C15 2.2uF

R12 2 2k R55 4 .7M C16 2.2uFR13 22k C18 2.2uF

R44 22k

R45 22K


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Resistors

100 1

470 1

1k 5

2.2k 8

10k 14

22k 6

51k 2

56k 1

100k 18

330k 4

470k 1

1M 4

4.7M 2

Total 67

It is highly recommended that you sort the bag of resistors into piles

before proceeding to assembly. Each diagrams is a screenshot of theboard with the component for that page highlighted. With the

components sorted, assembly will be more efficient.

The Resistor Color Code:

For the kit resistors, ignore the 3rd Band.


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Capacitors

10pF 2

1000pF 1

2200pF 2

4700pF 3

.022uF 4

.1uF 16

1uF 1

2.2uF 4

10uF 10

100uF 3

220uF 1

Total 47

-Note: For those who purchased kits, the kit ships with 5 values of capacitor that look almost

identical. Written on them is the capacitor code, but the kits were assembled in such a way that

the quantity of each of these similar-looking capacitors is also an indicator.

-Another Note: The radial capacitors (220, 100, 10, 2.2, and 1 uF) should be inserted so the

longer lead goes through the square hole. THIS IS DIFFERENT FOR THE LEDs.

220uF 100uF10uF 2.2uF

.1uF

2200pF

1000pF

1uF

10pF.022uF 4700pF


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*NOTE*

C5 Should be installed

OPPOSITE

of the indicated direction

on the board.


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Transistors

2N3904 7

2N3906 8

Total 15

The transistors’ physical shape should match the silkscreen of the component

from the top. Otherwise the transistor will not function properly.

Note: The transistors should be installed before the switches.


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Diodes

Red LED 6

8.2V Zener 1

4148 1

1N4001 1Total 9

The 1N4001 has the thickest leads, and the 4148 has tape on the ends.


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NOTE: The longer lead of the LED should go in the CIRCLE hole.

- This is different from the capacitors -


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Switches

Slide DPDT 10

Total 10

-Tip: Try and solder the support lugs for extra durability!


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Potentiometers

10k 4

50k 12

1M 9

Total 25

-Note: After the potentiometer has been inserted into the board, the legs canbe bent apart to ensure a strong hold of the board. This will keep torsion load

from twisting the knob from loading the active electrical solder joints.


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Jacks + Power

1/8" Mono Audio Jack w/ Switch 3

5.5mm DC Power Jack w/ Switch 1

1/4" Mono Audio Jack 2

PC Mount Battery Box 1

9V Battery 1

Total 8


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ICs + Sockets

14 Pin DIP Sockets 4

TLC556 2

CD 40106 1

TL074 1

Total 8

-NOTE Solder the sockets in, and then put 14 Pin ICs into the sockets toavoid overheating the ICs. All ICs should have their notch on the left.


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*The original power scheme for the Drone Lab involved adding a LM7809 voltage

regulator IC. However, we were unfortunately surprised to find that the 7809 slowly

consumed energy from the battery when the Drone Lab was switched off. Future

revisions will add diodes to stop this, but the 7809 is not really necessary becausethe Drone Lab’s IC’s can operate safely between 5V - 15 V. Simply install a jumper

wire or lead from the outer holes, and it will work fine. If you aren’t looking to use a

battery and need this regulator, it is commonly available and can be installed.


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There are two different hardware kits. The first is what ships with everyDrone Lab, and the second is for the Laser Cut housing plates.

Kit Hardware ( Component(Location) )

5/8” Flat Screw (Battery Box) 3

1/2“ Round Screw (Corners) 4

#4 Lock Washer (Corners) 4

#4 Nuts (Corners In Feet, Bat Box) 7

Rubber Feet (Corners, Bottom) 4

Total 22

Housing Hardware ( Component(Location) )

5/8” Flat Screw (Battery Box) 3

1 1/4“ Flat Screw (Corners) 4

1“ Flat Screw (Sides, Center) 3

#4 Nuts (Corners In Feet, Battery Box, Sides, Center) 14

#4 Lock Washer (Corners, Sides, Center) 7

Vinyl Standoffs (Corners, Sides, Center) 7

Rubber Feet (Corners, Bottom) 4

Total 42


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This isn’t the easiest to assemble kit out there. Still, with a little patience

and attention to detail, especially in creating great solder joints, the unitshould be able to be built within 8 hours. If it doesn’t work the first time donot despair, our units didn’t work the first try either.

Some Tips for Debugging:

- Look for missing or loose solder joints, cold solder joints can drive younuts! Look to heat up the surfaces of both the lead and pad such that thesolder forms a concave curve to the surfaces.- When in doubt use your Multi-Meter! Check for continuity where thereshould be, and where there shouldn’t be.- Follow the circuit schematic of failing systems. Look for abnormalitiesof continuity or missing / wrong direction components.- Keep Hope Alive. You’ll get it working soon enough! Remember to havefun, you’re building an analog synthesizer!


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Thanks again for your business, we hope you enjoy your Drone Lab. If you

have any questions, comments, or content, share it on the forums!

http://www.casperelectronics.com/ghostwizard/

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