Difference between revisions of "Kit assembly"

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'''Warning: make sure you have the VCC and GND pins wired correctly! Wiring them incorrectly will destroy the display the instant you power the phone on. '''
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'''Warning: make sure you have the VCC and GND pins wired correctly! Wiring them incorrectly will destroy the display instantly you power the phone on. '''
  
 
== Attaching keypad to front board ==
 
== Attaching keypad to front board ==

Revision as of 18:29, 1 April 2019

Zerophone Assembly Guide (Delta revision)

Resources

There are a few documents you can use to help you assemble your ZeroPhone:


If you get stuck or are unsure about something, feel free to ask for help on IRC (details on the wiki's frontpage).

Assembly

The assembly is split into two major parts:

FIXME: add pictures of typical SMD and through-hole components

You have to start by the SMDs since they are the smaller and trickiest parts and might not be accessible once the trhough-holes components are soldered. Your best friend is the interactive BOM, followed by the SMD assembly page (tips, details on marking, ...). We might be able to send you a board with the smallest and trickiest SMDs already soldered if you contact us :-)

Keypad

The keypad is a good start if you doubt your soldering skills: it's easy to solder and hard to mess up.

Suggested color-coding for the keypad


  • Delta keypad down.jpg
  • Delta keypad up.jpg
  • Soldered delta keypad up.jpg
  • Soldered keypad back delta.JPG


Resources:

Soldering orders:

  • Side buttons
  • Front buttons
  • Headers

Tip: In case you purchased side buttons without plastic pins that go into the PCB holes, you might want to superglue the buttons to the board before soldering them so they don't slip while soldering, as well as don't tear off as easily. You should then be careful while soldering, though, make sure to not let the fumes near your face.

Front board

-You might want to start soldering with the front board, it has TPA2005 (0.65mm pitch) and AtMega (0.8mm pitch) chips, it will give you the most challenge during soldering. Using solder wick will be helpful here.

Back board

This is the most component-heavy board of the ZeroPhone. Check that everything is in order before you solder the Raspberry Pi Zero, since some components won't be reachable after that.

Resources:

Soldering order:

  • SMDs
  • Headers
  • Charging port
  • GSM module
 * Add spacers between the GSM modem and the GSM pin plastic.
  • 5v step-up
  • USB port
  • USB wires
  • Raspberry Pi Zero

Upper/Front side

FIXME add pictures, details and tips

Lower/Back side

FIXME add pictures, details and tips

Jumpers

The first set of jumper depend on the model of display you use:

  • Heltec displays
  • Solder jumper configuration for Heltec displays

Warning: make sure you have the VCC and GND pins wired correctly! Wiring them incorrectly will destroy the display instantly you power the phone on.

Attaching keypad to front board

Before you do it

  • Make sure that soldering on any SMD components under the keypad looks good - it will be very hard to rework these components after attaching the keypad.
  • Make sure the 6-pin (ATMega) male header is attached to the front board
  • Make sure the 40-pin female header is attached to the front board, and the soldering is good (all the pins are well-connected).
  • Make sure that the 6-pin header pins won't interfere with the side button - if they do (i.e. you didn't add the 6-pin spacer between the 6-pin header and the PCB), you can either use flush cutters and cut into the solder joint, or use the soldering iron and push them further below the pins - the goal is making sure that 6-pin header pins do not touch the side button once the keypad is in place.

Workflow

  1. Using tin snips or cutters, make 2x 2-pin headers, 3x 3-pin headers and 1x 4-pin header. If you're attaching a keypad that uses the keypad GPIO, you need an additional 1-pin header for the GPIO pin - otherwise, it can be omitted.
  2. Using tin snips or cutters, trim the pin headers from one side so that both top and bottom metal parts have equal length.
  3. Put the front board on your desk / in your PCB holder with the top side upwards
  4. Put the pin headers into holes. Preferrably, with the non-cut side upwards.
  5. Seat the keypad board onto the headers - it should be parallel to the front board, and the outlines should match, we'll be checking further as we go.
  6. Solder the pin headers to pads on the keypad board. For each individual header, after soldering a single pin of it to the keypad PCB, check that there's no gap between the keypad PCB and header plastic - if there is, re-heat the solder joint and press them together until there's no gap. After you're done, you should have a keypad+headers combo.
  7. Flip the front board (together with the keypad), so that it's bottom side upwards. Solder a single pin of the keypad&header combo to the front board. Then, check the following steps (if anything's wrong, reheat the solder joint you just did and adjust the board until it's OK):
    1. the keypad is still parallel to the front board
    2. the keypad sits flush to the front board - there's no gaps between front board and pin header plastic, or pin header plastic and keypad board
    3. the keypad and front board outlines are still aligned
  8. Solder all the remaining pins. During soldering, check that there's no gaps between the front board and pin header plastic.
  • Step 1 and 2
  • Step 3 and 4
  • Step 5
  • Step 6