Assembly Soal Lks 2014

Number
ASSEMBLY
Time : 4.30 Hours
Maximum Score : 25 points
Assembly project LKS XXII-NAS-EL-2014
Page 1
1.0. INTRODUCTION:
Competitors are given 4.30 hours to complete an electronics assembly
project. This test project shall access competitors in the following areas:
Ability to assemble an electronic project based on given drawings,

specifications and instructions like:
Schematic Diagrams
PCB Layout Diagrams
Assembly Photographs
Component Part Lists
Ability to verify proper operation of an electronic project

after assembly like:
Interpret test specifications
Demonstrate proper operation of complete project
2.0. PROJECT DESCRIPTION

The device-under-construction is a Digital Power Supply Unit. It functions to
provide a well-regulated DC voltage from 0VDC to 15VDC, which can be set from its frontpanel control switches. Voltage and Current settings are adjustable digitally using a pair of
<+> and <->buttons each. These can increase or decrease voltage and current settings with
1V and 10mA resolutions respectively.
A Microchip Atmega16 microcontroller is used to handle the voltage and current setting
functions, and to monitor the actual output voltage and current levels. Both voltage and
current settings, and actual measurements are displayed on a 16 X 2 character LCD panel.
Current limiting can be set to a maximum of 2000mA, and for additional protection against
short-circuit currents, an additional over-current protection circuit is provided within the
power control board.
Page 2
Block diagram
The block diagram is shown in Fig 1.
Step Down 220

AC to 18 - 5 DC
18 V DC
5 V DC
MCU /
Mikrokontrol
Digital to
analog / R2R 10
bits
Buffer Transistor
ADC Voltage and

Current
V- OUT
Protector OUT
Fig 1. Block Diagram of Digital Power Supply Unit.
The Digital Power Supply Unit conforms to the following specifications:
Digital Power Supply Unit SPECIFICATIONS

NO
CRITERIA
REQUIREMENTS
1.
Rated Input Voltage
220 VAC (+/-) 10%
2.
Rated Output Voltage Span
3.
Set Voltage Accuracy
Set Voltage (+/-) 50mV
4.
Set Current-Limit Accuracy
Set Current (+/-) 100mA
5.
Output Voltage Ripple
0V to 15VDC
< 50mVAC
Page 3
The Digital Power Supply Unit can be operated with the following controls:
FRONT PANEL CONTROL

SYM
DESCRIPTION
FUNCTION
S1
SWITCH
Turn ON & OFF Power Supply Unit
S2
MENU
Navigate continuously through the following

modes:
S3
UP
Increase Set Voltage or current
S4
DOWN
Decrease Set Voltage or current
S5
OK
Program Run / Function
JA
+OUTPUT
Power Supply DC Output Voltage (+)
JB
-OUTPUT
Power Supply DC Output Voltage (-)
LCD 1
LCD PANEL
Display File List and the operation of product
Fig 2 Front Panel Controls & Display
Page 4
3. Parts list
3.1Main PCB
No
Quanti
ty
Value
Description
Part Number
0.33
Resistor, 5W, 5%
R26
470
Resistor, 0.25W, 5%
R31
1k
Resistor, 0.25W, 5%
R24,R33
1k8
Resistor, 0.25W, 5%
R32
11
10k
Resistor, 0.25W, 5%
R2, R4, R6, R8,

R10, R12, R14,
R16, R18, R21, R23
5k6
Resistor, 0.25W, 5%
R25
12
20k
Resistor, 1W, 1%
R1, R3, R5, R7, R9,

R11, R13, R15,
R17, R19, R20, R34
4k7
Resistor, 1W, 1%
R22, R29, R30
1K
Multi turn variable resistor
VR1
10
22pF
Capacitor SMD 1206
C1, C2,
11
100nF
Capacitor SMD 1206
C3, C4, C5, C9,

C12
10uF/25V
Capacitor, Electrolytic, 2 mm
pitch,
12
C8,
4 mm dia
12
470uF/25V
Capacitor, Electrolytic, 2 mm
pitch,
C6, C10, C11
4 mm dia
13
4700uF/25
V
Capacitor, Electrolytic, 7.5 mm

pitch,
C7
16 mm dia
14
IN4001
Diode 1 A
D1
15
1N5408
3A General Purpose Plastic

Rectifier
D2, D3, D5, D6
16
1N5400

Rectifier
D4
17
1N4148
D7
Page 5
Rectifier
18
8V2
Diode zener 1 watt
DZ1
19
LED3MM
Red, 2.54 Pitch
LED1,
20
2N2222
SMD Transistor NPN
Q5, Q6
21
BC547
Transistor NPN
Q2
22
BC557
Transistor PNP
Q1
23
BD137/DB1
39
Transistor NPN
Q3
24
BD245/TIP
35
Transistor NPN
Q4
25
LM7805
5 V 1A Step-Down Voltage
Regulator,
U2
26
LM7812
12 V 1A Step-Down Voltage
Regulator,
U3
27
Atmega16
A
Microcontrollers, DIP 40 Pin
U1
28
11.059200
MHZ
SMD Crystal, Load Capacitance

10,0pF to 75.0pF
Y1
29
TMB12A05
Buzzer
Sp1
30
B3F-1020
Push buttom size 5 mm
S1
31
Relay
Relay 12 Volt 5 pin
RL
32
R-aray
10 K, 9 pin
RA
33
1x5
Pinhead
5 Pin, Male, Pin Header, 2.54 mm

Pitch
P1, P3
34
1x9
Pinhead
9 Pin, Male, Pin Header, 2.54 mm

Pitch
P4,
35
T-blok 2 pin
2-Pin Terminal Blok, M2.5,
P1, P2
36
HDR. soc
MHDR 1x2
P7
37
2x20
40 pin socket IC, 2,54 mm Pitch
3.2 Panel PCB

No
Quanti
ty
Value
Description
Part Number
Page 6
270
Resistor SMD 1206
R35
1k
Resistor SMD 1206
R36
10K
Multi turn variable resistor
VR2
B3F-4050
Tactile Switch size 12x12 mm,

DC 24 V, 50 mA
SW1, SW2, SW3, SW4,
TG12864E
-01XWBV
16x2 Graphic LCD
LCD1
3.3 box
No
Quanti
ty
Value
Part
Description
Number
AC Cord Cable
Fan DC 12 Volt, 60x60mm
Fan nets 60x60 mm
Banana socket red 8mm
Banana socket black 8mm
Heatsink for LM78xx
10
1.5 m
Wire, 18 AWG, Black
11
1.5 m
Wire, 18 AWG, Red
12
0.5
13
20 cm
14
Spacer, Brass, Hexagonal, M3x10 mm
15
Screw Pan Head M3x8mm
16
770W-
Inlet, 250V, 2.5A, 28x16 mm, 0.6~2.0 mm
X2/12
Panel Thickness + fuse
SLE10A2
Rocker Switch, 125VAC, 10A, SPST, 2cm

Step Down Transformer, 110/220/230
primary, 0-24 V
Kabel
layer cable, 10 layer

Shrinkable Tubing, Black, red,4.8
Screw, Pan Head, Brass, Nickel Plated,

M3x10 mm
Page 7
P3
S1
T1
F1
17
18
19
Hexagonal Nut M3
20
Hexagonal Nut M4
21
10
22
M3x25 mm
M4x10 mm
Cable Ties, 2.4x140 mm

Acrylic Casing 225 x 17 mm
1. Assembly Process
READ ALL INSTRUCTION FROM WORKSHEET
Page 8
1.1.
Assemble Main PCB (single Layer)

Assemble the Main PCB referring to the Main PCB Schematic and Main PCB
parts list. Assemble capacitor SMD, Xtal SMD, Transistor SMD, Resistor 0.25 watt,
Dioda, Resistor 5 watt, Push Button, IC Sockets, Capasitors, Elco, Transistor, IC
regulator and Socket for IC on Main PCB.
fig3. Top Overlay Main PCB
Fig4. Bottom Overlay Main PCB
Page 9
Fig5. Layout PCB, Upper layer
Page 10
Fig6. Layout PCB, bottom layer
1.2.
Assemble Panel PCB (double Layer)

Assemble the Front PCB referring to the Front PCB Schematic and Front PCB
parts list. Assemble Resistor SMD, multitrun resistor, Push Button, lcd 16X2.
Fig7. Top
Overlay panel PCB
Page 11
Fig8. Bottom Overlay panel PCB
Fig9.
Layout PCB, Top layer
Page 12
Fig10. Layout PCB, bottom layer
Page 13
4. Schematic
a. Main schematic
Page 14
Fig 5. Main Schematic Microcontroller Section
Page 15
Fig 6. Main Schematic Power Supply Section
Page 16
B. Panel schematic
Fig7. Panel Schematic
Page 17
5. Chassis and Mechanical for Digital Power Supply Unit.

5.1 Front & Rear Panel Assembly
Fig 8. Front Panel Controls & Display
5.2 Assemble F1 and FAN to the Chassis Rear Panel. FAN is attached using
M3 X 25mm Screws and M3 Nuts
Fig 10. Rear View
Page 18
5.3 Chassis Assembly

consider the installation of a fan
win
d
Fig 11. Main PCB Assy
Fig
12.
AC Power Connection
Page 19
AC
Fig 13.
Power Connection
Fig 14. Output Connection
Page 20
Assemble Push Button on Upper Side of PCB, give clearance +- 3mm from
give clearance +- 3mm

from PCB
PCB.
Fig 15. Assemble Push Button
flat
Connection LCD to main board (P3 to P8 and P4 to P9) and position
must be flat.
Fig 16. Connection LCD

Page 21
switchs with acrylic
Bottom View
Fig 17.
Page 22
Fig 17. Acrylic Design
6. Setting and Adjustment
Page 23
After the competitor completing the assembly project in accordance with the existing
scheme of the question paper properly, then the competitor should check and setting of the
functions project, follow the steps :
1.
2.
3.
4.
Connect the AC connector on the power supply PLN 220.

Turn on the circuit by pressing the ON button to switch ON - OFF AC.
Setting 10 Kohm variable resistor to adjust the LCD contrast.
Turn on the power supply voltage of 10 Volts output position in the follow the steps :
setting default
-
Pressing the "menu"

Then will be shown following screen "manual settings? And then select "OK"
Then will be shown following screen "setting = 3:00 V and then select " NO "
Then will be shown following screen "default 5 V? And then select "NO"
Then will be shown following screen "default 10 V? And then select "OK"
or by setting it manually with the following:

- Pressing the menu"
- Then will be shown following screen "manual settings? and then select "OK"
- press the " UP " to indicate voltage 10 V.
- After that press "OK".
5. Connect the power supply output measuring devices volt multitester in size, Adjust
VR1 to getting the same value between reading volt meter with LCD display.
Fig 17. Adjustment
Page 24

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Number

Assembly project LKS XXII-NAS-EL-2014

Ability to assemble an electronic project based on given drawings,

Ability to verify proper operation of an electronic project

2.0. PROJECT DESCRIPTION

Assembly project LKS XXII-NAS-EL-2014

Step Down 220

ADC Voltage and

Fig 1. Block Diagram of Digital Power Supply Unit.

The Digital Power Supply Unit conforms to the following specifications:

Digital Power Supply Unit SPECIFICATIONS

Rated Input Voltage

220 VAC (+/-) 10%

Rated Output Voltage Span

Set Voltage Accuracy

Set Voltage (+/-) 50mV

Set Current-Limit Accuracy

Set Current (+/-) 100mA

Output Voltage Ripple

Assembly project LKS XXII-NAS-EL-2014

FRONT PANEL CONTROL

Turn ON & OFF Power Supply Unit

Navigate continuously through the following

Increase Set Voltage or current

Decrease Set Voltage or current

Program Run / Function

Power Supply DC Output Voltage (+)

Power Supply DC Output Voltage (-)

Display File List and the operation of product

Fig 2 Front Panel Controls & Display

Assembly project LKS XXII-NAS-EL-2014

R2, R4, R6, R8,

R1, R3, R5, R7, R9,

R22, R29, R30

Multi turn variable resistor

Capacitor SMD 1206

Capacitor SMD 1206

C3, C4, C5, C9,

C6, C10, C11

Capacitor, Electrolytic, 7.5 mm

3A General Purpose Plastic

D2, D3, D5, D6

3A General Purpose Plastic

1A General Purpose Plastic

Assembly project LKS XXII-NAS-EL-2014

Diode zener 1 watt

Red, 2.54 Pitch

SMD Transistor NPN

Microcontrollers, DIP 40 Pin

SMD Crystal, Load Capacitance

Push buttom size 5 mm

Relay 12 Volt 5 pin

5 Pin, Male, Pin Header, 2.54 mm

9 Pin, Male, Pin Header, 2.54 mm

2-Pin Terminal Blok, M2.5,

40 pin socket IC, 2,54 mm Pitch

3.2 Panel PCB

Assembly project LKS XXII-NAS-EL-2014

Resistor SMD 1206

Resistor SMD 1206

Multi turn variable resistor

Tactile Switch size 12x12 mm,

SW1, SW2, SW3, SW4,