LKS 2016 TP16 Asp en

ASSEMBLY PROJECT
Test Project Document

LKS_2016_EA_ASP_EN
Submitted by:
Name : Ina skills Electronics
Member : ASC WSC Team ID
Type : Open Project
Time : 4 Hours
Point : 25 Points
Test Project for skill 16 Version: 1.0

LKS_2016_EA_ASP_EN Date: 10.12.14 Page 1 of 31
www.inaskills-electronics.com
Contents
This Test Project proposal consists of the following documentation/files:
1. LKS_2016_EA_ASP_EN.doc
2. LKS_2016_EA_ASP_01_EN.pdf

1. INSTRUCTIONS
Competitors are given 3 hours to complete an electronics assembly project. This test project
shall access competitors in the following areas:
a. Ability to assemble an electronic project based on given drawings, specifications and

instructions like :
 Schematic Diagrams
 PCB Layout Diagrams
 Assembly Photographs
 Component Part Lists
 Component Data Sheets
b. Ability to verify proper operation of an electronic project after assembly like :
 Interpret test specifications

 Demonstrate proper operation of complete project
2. DESCRIPTION PROJECT AND TASKS

Assembly of this project is the digital power supply. The microcontroller used in the circuit
is ATMEGA 16, a member of Atmel’s AVR microcontroller family. The main features of the power
supply are the adjustable output voltage level and protection current limiter. Character 16x 2 of
LCD is used as a control interface to set the parameters of voltage and current, and as displays for
monitoring the actual values of voltage and current parameters that must be controlled. The output
voltage of this device is 0-13 volts and the current is 1.5 amperes.

Block diagram
Display
DAC Voltage Current

Switches Converter
Microcontroller Amp. Amp
ATmega 16
Protector
Output
Voltage Current
sensor sensor
- +
Out Out
Fig 1 block diagram
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 0V to 13VDC
3. Set Voltage Accuracy Set Voltage (+/-) 100mV
4. Output Voltage Ripple < 50mVAC
The Digital Power Supply Unit can be operated with the following controls:
FRONT PANEL CONTROL

SYM DESCRIPTION FUNCTION
SW1 SWITCH Turn ‘ON’ & ‘OFF’ Power Supply Unit
S2 MENU Navigate continuously through the following modes:
S3 UP Increase Set Voltage
S4 DOWN Decrease Set Voltage
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 3D view

3. INSTRUCTION TO THE COMPETITOR
Time limit is 3 hours.
3.4 Complete this Assembly Project using given materials and documents.
 Diagram list
 Schematic : Main PCB, Panel PCB
 Component Layout : Main PCB Top, Main PCB Bottom, Panel PCB Top, Panel PCB
Bottom
 Photographs for assembling
 Operating description
 Parts list
 Parts datasheet
3.5 After you complete the assembling, then check these points below.
3.5.1 Adjustment voltage output
Before the device uses, appropriate output voltage with voltmeter.
a. Turn on switch ‘SW1’
b. Press ‘menu’ button
- Will be shown following screen
Fig 3 Setting mode
c. Choose yes or Press ‘ok’ button for setting

Fig 5 setting mode
a. Press ‘UP’ or DOWN button repeatedly to set voltage (7.50V).

Fig 6 Setting mode
d. Press ‘ok’ button for Running

Fig 7 Running mode
e. Adjust voltage output with voltmeter

- Adjust VR1 until value voltmeter same as LCD display
Fig 8 Adjustment voltage
3.5.2 standby Mode

b. Turn on switch ‘SW1’
Fig 10 first display

3.5.3 Manual Mode Setting

Fig 11 setting mode

Fig 12 setting mode
d. Press ‘UP’ or DOWN button repeatedly to set voltage.
Fig 13 setting mode
e. Press ‘ok’ button for Running

Fig 14 running mode

3.5.4 Default Mode Setting

Fig 15 setting mode

Fig 16 setting mode
d. Press ‘menu’ button for default setting

Fig 17 default 5 Volt
- Press ‘menu’ button for change voltage default setting

- Press ‘menu’ button for change voltage default setting
e. Press ‘ok’ button for Running

Fig 20 running mode
3.5.5 Memory Mode

Fig 21 setting mode
c. Choose ‘NO’ or Press ‘menu’ button for call memory

- Program will be previous running memory data

4. Parts list (BOM)
4.1 Main PCB
No Quantity Value Description Part Number
1 1 0.33 Resistor, 5W, 5% R35
2 1 470 Resistor SMD 0805 R2
3 1 1k Resistor SMD 0805 R5
4 1 1k8 Resistor SMD 0805 R31
5 3 4k7 Resistor SMD 0805 R1, R30, R32
6 1 5k6 Resistor SMD 0805 R34
R3, R16, R17, R18, R19,
7 15 10k Resistor SMD 0805 R20, R21, R22, R23, R24,
R33, R26, R27, R28, R29
R4, R6, R7, R8, R9, R10,
8 12 20k Resistor SMD 0805 R11, R12, R13, R14, R15,
R25
9 1 10K Multi turn variable resistor VR1
10 2 22pF Capacitor SMD 0805 C10, C11,
11 5 100nF Capacitor SMD 0805 C6, C8, C9, C12, C13
Aluminium electrolytic
12 2 10uF/35V C3, C5
capacitors, 5× 5 dia
Aluminium electrolytic
13 2 470uF/25V C4, C7,
capacitors, 10× 10 dia
Capacitor, Electrolytic, 2 mm
14 1 2200uF/25V C1
pitch, 12 mm dia
Capacitor, Electrolytic, 2 mm
15 1 4700uF/25V C2
pitch, 16 mm dia
16 2 IN4001 Diode 1 A, footprint DO-41 D2, D6

Bridge diode 3A, size
17 1 KBPC308 D1
15.9x15.9 mm
3A General Purpose Plastic
18 1 1N5401 D7
Rectifier, footprint DO-201AD
1A General Purpose Plastic
19 1 1N4148 D4
Rectifier, footprint DO-35
20 1 8V2 Diode zener 1 watt DZ1
21 1 RED LED led SMD 0805 D3
SMD Transistor, footprint NPN
22 2 2N2222 Q1, Q2
SOT23_N
Transistor NPN footprint
23 1 BC547 Q3
SOT54
Transistor PNP footprint
24 1 BC557 Q4
SOT54
25 1 DB139 Transistor NPN Q5
26 1 TIP35 Transistor NPN Q6

5 V 1A Step-Down Voltage
27 1 MC78M05 U1
Regulator, footprint 369A-03
12 V 1A Step-Down Voltage
28 1 MC78M12 U2
Regulator, footprint 369A-03
Microcontrollers, footprint
29 1 Atmega16A - AU U3
44A_N
SMD Crystal, Load
30 1 11.059200 MHZ Y1
Capacitance 10,0pF to 75.0pF
31 1 TMB12A05 Buzzer BZ1
32 1 B3F-1020 SMD Push button size 5 mm S1
Relay 12 Volt, 5 pin, SPDT,
33 1 Relay RL1
omron
2x5 pin Male
10 Pin, male, Pin Header, 2.54
34 1 Header With P4
mm Pitch
cover ST
1x6 male Header 6 Pin, Male, Pin Header, 2.54
35 1 P3
single ST, yellow mm Pitch
2-Pin Terminal Blok, 5 mm
36 2 T-block 2 pin P1, P5
Pitch
1x2 white
37 1 MHDR 1x2, 2.54 mm Pitch P2
connector
X1, X2, X3, X4, X5, X6, X7,
38 9 1 pin plug 1 pin test point
X8, X9
4.2 Panel PCB

1 1 270 Resistor SMD 0805 R36
2 1 5K Multi turn variable resistor VR2
3 1 100nF Capacitor SMD 0805 C14
Register IC SMD, footprint
4 1 SN74HC595D U4
D016_N
Tactile Switch size 12x12 mm,
5 4 B3F-4050 SW1, SW2, SW3, SW4,
DC 24 V, 50 mA
6 4 knob Tactile Switch square knob Switch

TG12864E-
7 1 16x2 alphanumeric LCD LCD1
01XWBV
2x5 pin Male
10 Pin, male, Pin Header, 2.54
8 1 Header With P6
mm Pitch
cover ST
9 3 Plug 1 pin Plug test point 1 pin X10, X11, X12

4.3 Power Supply Box
1 1 AC Cord Cable
770W- Inlet, 250V, 2.5A, 28x16 mm, 0.6~2.0 mm Panel
2 1 P7
X2/12 Thickness + fuse
3 1 SLE10A2 Rocker Switch, 125VAC, 10A, SPST, 20 mm dia SW1
Step Down Transformer, 110/220/230 primary, 0-
4 1 T1
18V
5 1 Fan DC 12 Volt, 60x60mm F1
6 1 Fan nets 60x60 mm
7 2 IDC socket S10 - A1 P4’, P6’
8 1 Banana socket red, 8mm dia JA
9 1 Banana socket black, 8mm dia JB
10 1 Heat sink for TIP35 35mmx12.5mm
11 1.5 m Wire, 18 AWG, Black
12 1.5 m Wire, 18 AWG, Red
13 20 cm layer cable, 10 layer
14 15 cm Shrinkable Tubing, Black, 4mm dia
15 15 cm Shrinkable Tubing, red, 4mm dia
16 8 Spacer, metal, Hexagonal, M3x10 mm
17 7 Screw Pan Head, metal M3x8mm
Screw, Pan Head, Brass, Nickel Plated,
18 4
M3x35mm
Screw, Pan Head, Brass, Nickel Plated, M4x8
19 2
mm
20 6 Hexagonal Nut M3, metal
21 2 Hexagonal Nut M4
22 10 Cable Ties, 2.5x100 mm
23 1 Acrylic Casing 19 x 14 x 6 cm

4.4 Equipment, machinery, installations and materials required.
Proposal committee prepares the following equipment, machinery, installations and
materials.
Item Qty Material Description Notes
1 1set All parts
2 1 Safety glass
3 1 Cotton Glove
Competitor prepares the following equipments, machinery, installations and materials.

Item Qty Material Description Notes
Universal Digital or Multi-

2 1 V, Ω, A, etc
meter
3 1 Soldering Iron
4 1 Soldering Iron Stand
5 1 Solder attractor
6 1 Pincer
7 1 Nipper
8 1 Wire Stripper
9 1 Tweezers
10 1 Precise screwdriver For trimmer resistor
11 1 Screw driver + type
12 1 Screw driver - type
13 1 Brush
14 Ect…

5. Assembly process
Make sure all components is completed
Fig 22 All component
5.1 Main PCB assembling

Assemble the Main PCB referring to the Main PCB Schematic and Main PCB parts list.
Specification for height
(1) IC ATmega 8 : should be mounted ‘home’ onto the PCB surface.
(2) Capacitor and Resistor should adhere to the PCB surface.
(3) Transistors: 5mm – 7mm away from the PCB surface.
Fig 23 Main PCB top

Fig 24 Main PCB top, After Assembly
Fig 25 Main PCB Bottom

Fig 26 Main PCB bottom, After Assembly
5.2 PANEL PCB assembling

Assemble the Front PCB referring to the Panel PCB Schematic and Panel PCB parts list.
a. Combine LCD and Front PCB with a 16 pin Header.
Fig 27 combines LCD with a 16 pin header

b. Assemble capacitor, Resistor, IC, test point, variable resistor and header 2 x5 pin on
the Bottom Side of PCB.
Fig 28 Panel PCB bottom
Fig 29 Panel PCB bottom, After Assembly

c. Assemble LCD and push button on the Top Side of PCB.
Fig 30 Panel PCB Top
- Assemble Push Button on Upper Side of PCB, Give clearance +- 3mm from
PCB.
Fig 31 Assemble Push Button

- Assemble LCD on Upper Side of PCB
Fig 32 Assemble LCD
Fig 33 Panel PCB Top, After Assembly

5.3 Assemble and wiring the power installation.
a. Assemble Inlet AC, Fan, Fan nets, Rocker Switch, Transformer, banana socket on the
box acrylic.
Fig 34 Assemble accessories
Fig 35 assemble Inlet AC

Fig 36 assemble Transformer
Fig 37 assemble Rocker Switch

Fig 38 assemble Banana socket
Fig 39 Assembly fan and net fan net

b. Assemble and wiring the power installation.
Fig 40 wiring power installation
c. Assemble main PCB and panel PCB on the box acrylic.
Fig 41 Assemble main PCB and panel PCB

Fig 42 Assemble main PCB
Fig 43 Assemble panel PCB

d. Wiring connection.
Wire up interconnections according to ASC2014_TP16_VN_ID_06_EN.pdf,
installation Diagram.
Fig 44 Wiring connection
Fig 45 Wiring Inlet AC

Fig 46 Wiring transformer primary (0 – 220 V)
Fig 47 Wiring transformer secondary (0 – 18 V)

Fig 48 wiring rocker switch
Fig 49 Wiring banana socket

Fig 50 Wiring banana socket
Fig 51 Wiring IDC socket

Fig 52 length IDC socket
Fig 53 length IDC socket
40 CM ± 0.5 cm
Fig 54. length DC socket

SELAMAT BERLATIH !!!
Discussion forums: www.inaskills-electronics.com


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ASSEMBLY PROJECT

Test Project Document

Test Project for skill 16 Version: 1.0

Test Project for skill 16 Version: 1.0

a. Ability to assemble an electronic project based on given drawings, specifications and

b. Ability to verify proper operation of an electronic project after assembly like :

 Interpret test specifications

2. DESCRIPTION PROJECT AND TASKS

Test Project for skill 16 Version: 1.0

DAC Voltage Current

Fig 1 block diagram

The Digital Power Supply Unit conforms to the following specifications:

Digital Power Supply Unit SPECIFICATIONS

FRONT PANEL CONTROL

Test Project for skill 16 Version: 1.0

Test Project for skill 16 Version: 1.0

Time limit is 3 hours.

Fig 3 Setting mode

c. Choose yes or Press ‘ok’ button for setting

Fig 5 setting mode

a. Press ‘UP’ or DOWN button repeatedly to set voltage (7.50V).

Test Project for skill 16 Version: 1.0

d. Press ‘ok’ button for Running

Fig 7 Running mode

e. Adjust voltage output with voltmeter

Fig 8 Adjustment voltage

3.5.2 standby Mode

Fig 10 first display

Test Project for skill 16 Version: 1.0

a. Turn on switch ‘SW1’

Fig 11 setting mode

c. Choose yes or Press ‘ok’ button for setting

Fig 12 setting mode

d. Press ‘UP’ or DOWN button repeatedly to set voltage.

Fig 13 setting mode

e. Press ‘ok’ button for Running

Fig 14 running mode

Test Project for skill 16 Version: 1.0

a. Turn on switch ‘SW1’

Fig 15 setting mode

c. Choose yes or Press ‘ok’ button for setting

Fig 16 setting mode

d. Press ‘menu’ button for default setting

Fig 17 default 5 Volt

- Press ‘menu’ button for change voltage default setting

Fig 18 default 10 Volt

Test Project for skill 16 Version: 1.0

Fig 19 default 12 Volt

e. Press ‘ok’ button for Running

Fig 20 running mode

3.5.5 Memory Mode

a. Turn on switch ‘SW1’

Fig 21 setting mode

c. Choose ‘NO’ or Press ‘menu’ button for call memory

Test Project for skill 16 Version: 1.0

16 2 IN4001 Diode 1 A, footprint DO-41 D2, D6

Test Project for skill 16 Version: 1.0

4.2 Panel PCB

6 4 knob Tactile Switch square knob Switch

Test Project for skill 16 Version: 1.0

Test Project for skill 16 Version: 1.0

Item Qty Material Description Notes

1 1set All parts