Dongle Assembly Manual - Seasonal Entertainment

xDONGLE
USB to DMX Dongle – Fully ENTTEC Pro Compatible
Assembly Manual
40 State Route 23 North
Suite 1A
Riverdale, NJ 07457
P: 973-831-2822
Introduction
Congratulations on your purchase of the xDongle. The kit contains all the parts necessary to construct a
fully functional xDongle. This device, used in conjunction with any computer, will create one full 512
channel DMX network. This fully Enttec compatible DMX dongle is a great alternative for a DMX dongle.
The device features a USB-B connector on the input side and an 3 pin XLR connector or DMX standard
Cat-5 connector on the output side. Power and DMX status LEDs help the user see when the device is
power and when DMX data is being transmitted. The device comes in a fully anodized aluminum case
and features fully isolation to keep your DMX devices and your computer safe. FTDI USB processor and
drivers ensure reliable operation on either a Windows based PC or a Mac based operating system.
Please take the time to read the following sections of this manual. Enclosed in this document is
information regarding assembly, parts and tools required. Be sure to do an inventory of all the parts
before starting to ensure your familiarity with the parts. Even if you have never soldered something
before, this unit should be something a novice could construct.
*Disclaimer! This device uses potentially deadly voltages in operation. If you do
not feel it is within your ability to work with these voltages please stop and get
assistance, or purchase a ready built product. Improper use of this equipment
could be hazardous to life and property and the suitability of use is your
responsibility. Seasonal Entertainment assumes no responsibility in the use or
operation of this equipment.
Tools
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Long nose or needle nose pliers
Wire nippers
25 watt soldering iron
Magnifying glass (lighted if possible)
Solder
Assembly Instructions
Before you begin, make sure all the PCB’s arrived in good shape. Check the traces; look for any markings
on the PCB; check to make sure you received all your components and LED’s. One PCB should look like
the following:
In the event that there are issues with the board, please do not continue on and contact us via the Help
Desk.
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A Quick Lesson on Soldering
Soldering is a skill that is only learned through practice. If this is your first time soldering a circuit board,
take the time to read over these steps and practice on a spare or practice PCB. The ability to solder
properly could determine the lifespan of the product and how well it functions. Below are a few
pictures to help guide you in your understanding of soldering.
With this kit, you will need to provide your own solder. Do not make the mistake of using plumbing
solder or acid core solder. This type of solder will damage the PCB and cause the unit to become
useless. Thin, rosin core solder is designed for use with electronics
and should be used for this application. A local electronics store or
RadioShack will sell this type of solder.
To begin, be sure that the circuit board is clean and all the traces
are intact and not broken at any point. Also be sure the soldering
iron is fully heated and the tip is clean. Having a sponge or a Tip
Cleaner (pictured) nearby is very useful.
When inserting components into the circuit board, be sure to bend the
ends just a little bit to hold it in place. This will allow you flip the
circuit board over and have the component held in place while you
solder.
Next you should place the tip of
the soldering iron directly on the
board foil of the circuit board, next to the component lead. Allow
the heat to transfer and touch the other side of the lead with the
solder. The solder should flow evenly onto the lead and the foil
making a good connection. It is very important to make sure you
are applying heat to both the component and the board foil. If just
the board foil is being heated, then the solder will not hold to the component. At the same time, if just
the component is being heated, then the solder will not hold to the board foil.
Once the solder has cooled, use wire nippers to cut the remaining component leads up against the
solder.
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Part Description
1.1 USB Interface IC
The USB Interface IC is used to connect the dongle to the computer’s USB COMM Port. This device
is extremely small and a SMD. Most novice electronics builders do not have the ability to properly
solder these small devices. Whether you purchased this kit fully assembled or a DIY device, this chip
will already be soldered onto the PCB.
1.2 Resistors
Resistors are specified by their resistance value in ohms. On this particular product, there are four
different resistors used, at different values. The polarity or way the resistors are inserted into the
board does not matter, as resistors do not have a polarity. Make sure that the resistors are placed
firmly up against the circuit board and the leads are cut as close to the solder as possible. Be sure to
read and understand the markings listed below to insert the proper resistor in the proper location.
1.3 Capacitors
A capacitor, when taken down to its bare roots, stores electricity. Because of this, it is very
important to understand a capacitor’s orientation on the PCB. The circuit board has a printed “+”
marked next to a square solder pad. Be sure to align the minus/plus on the capacitor with the
equivalent marking on circuit board. If your capacitor only has the minus marked, then put the
unmarked lead of the capacitor in the “+” hole. Usually the capacitor has a gray line down one side.
This is the negative side. This project also uses capacitors that do not have a polarity. It does not
matter how these are installed into the board. You should install them the same way you install a
resistor.
1.4 RS485 Interface
The RS485 chip translates the signal received from your DMX network and puts it into a language
that the controller can understand. There is only one of these 8 pin chips on this board.
1.5 Crystal
The crystal on this board is used to regulate the speed of the transmission of the DMX signal.
1.6 EMI Filter Bead – Ferrite Bead
A ferrite bead is used to suppress high frequency noise on a data line. These devices help prevent
interference with data going in more than more direction. There is one bead used on this device. It
has no polarity so install it like you would a resistor and trim the leads on the opposite side of the
PCB.
1.7 Optocouplers
Optocouplers are a safety device that are used to isolate the higher voltage used to control the
lights with the lower voltage used in your computer. Without these devices, in the event of a sort,
that power could travel back to your computer and fry some of the components in your computer,
or worse, your entire computer. There is no actual physical electrical connection in this device,
which is how the isolation is done. Be sure to match the notch or dot to the notch on the silkscreen.
1.8 MOSFET
A MOSFET acts as an on/off switch for the voltage. However, with the electronics on the board the
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switch can be faded on and off very easily and smoothly. These particular MOSFETs are in the TO-92
shape. These are much smaller than standard MOSFETs and allow us to keep the board small. Be
sure to insert them into the board according to the silkscreen
1.9 Integrated Circuit
The Integrated Circuit (IC) in this kit has already been programmed. Located on the processor is
either a notch or a dot stamped or printed on the IC. This will indicate which pin is “Pin 1.” Printed
on the circuit board is a silk screen showing which direction the notch should face. It is very
important to orient, not only the IC, but also the socket correctly.
1.10 LEDs
LED’s have two leads. The longer of the two leads is the positive side of the LED and should be
inserted into the round hole on the circuit board. This kit uses two 3mm LED which are smaller than
standard LEDs. The LEDs should be installed higher off the board so they can be bent to fit into the
enclosure
1.11 Modular Jack
A modular Jack is a component used to easily connect Cat-5 cable to any device. All internal wiring
is completed and the device is ready to be installed into your circuit board. Be sure that all 8 pins
are inserted into the circuit board before pushing the black tabs into the holes.
1.12 Sockets
This kit uses sockets to easily insert and easily remove IC Chips. The sockets used in this kit are 8 pin
and 28 pin sockets. The pins on the sockets are bent to hold them onto the PCB until they are
soldered in placed
1.13 Header
This design uses one 6 pin header used to connect a programming header to update the firmware
on the controller. There is no orientation and the header can be installed any way you wish.
1.14 DC-DC Converter
The particular DC/DC Converter used in this product is a fully isolated converter. This allows a
complete electrical separation between the electrical components on the device. The DC/DC
Converter used on this board is rated at 1000 volts. The leads may hang low after soldered so if they
do you should cut them off.
1.15 3 Pin XLR Jacks
This product uses 3pin female XLR jack. This jack is needed if you plan on using any sort of XLR
connections to your DMX devices
1.16 USB-B Right Angle Connector
The dongle receives its power and data from a USB-B cord. The cord connects to a right angle
connector. There are 4 data pins and 2 mounting/grounding pins. Be sure they all get installed and
soldered to the PCB
1.17 Enclosure and Screws
This product comes equipped with a black anodized aluminum enclosure. This enclosure features
two different end plates and all the screws necessary to attach the end plates. Further instruction
on installing that circuit board in the enclosure can be found below. There are also two additional
screws to attach the XLR jack to the enclosure.
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Parts List:
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Kit should include all items listed below
Quantity
Identification
1
4
PCB
R1, R2, R3, R5
2
R6, R7
1
R4
1
C2
1
C9
4
C1, C6, C7, C8
2
C3, C4
1
C5
1
1
1
1
L1
Q2
J1
X3
1
1
1
1
1
1
1
1
1
1
1
2
1
X1
Q1
U4
U3, OPT1 (socket only)
LED1
LED2
U3
OPT1
F1 (Sockets, fuse, fuse cover)
USB Cord
Enclosure
Black Screws
U2
Description
Printed Circuit Board
1/4W, 10KOhm Carbon
Film Resistor
1/4W, 330 Ohm Carbon
Film Resistor
1/4W, 470 Ohm Carbon
Film Resistor
Ceramic Capacitors 0.01uF
50 volts
Aluminum Electrolytic
Capacitor 100uF 25V
Ceramic Capacitors 0.1uF
50 Volts
Ceramic Capacitors 22Pf
100V
Tantalum Capacitor 4.7uF
16V
Ferrite Bead
MOSFET P-Channel
Right angle Modular Jack
Right angle 3 pin Female
XLR Jack
USB-B Connector
16MHZ Crystal
DC/DC Converter
8 Pin sockets
Red 3mm LED
Green 3mm LED
RS485 Buffer/Line Driver
Optocoupler
Fuses and sockets
“B” Style Connector
USB Interface IC USB to
Parallel
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Part Markings
xDongle
Brown, black, orange,
gold
Orange, orange, brown
gold
Yellow, violet, brown,
gold
Round yellow ball
Round yellow balls
1C51AJ
Female XLR Jack
USB-B Connector
16.000
NMR100C
ST485BN
6N137
10 amp fuse
xSplit
XLR Jack
Already installed on PCB
Completed xDongle
*Actual board may vary depending on board version
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Assembly 1 of 6: Resistors
Use fine gauge solder unless
otherwise instructed in this document
[ ] R1, R2, R3, R5: 10KOhm Carbon Film Resistor
[ ] R4: 470 Ohm Carbon Film Resistor
[ ]R6, R7: 330 Ohm Carbon Film Resistor
Insert resistor, solder on reverse side,
than trim off excess leads
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Assembly 2 of 6: Non-Polarized Capacitors
Use fine gauge solder unless
otherwise instructed in this document
[ ] C2: .01uF CeramicCapacitor
[ ] C3, C4: 22pF Ceramic Capacitors
[ ] C1, C6, C7, C8: .1uF Ceramic Capacitors
Insert capacitors, solder on reverse
side, than trim off excess leads
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This capacitor looks like the rest
but is very important. Look for
the marking on the edge pieces!
Assembly 3 of 6: Sockets and Ferrite Bead
Use fine gauge solder unless
otherwise instructed in this document
[ ] U3, OK1: 8 pin sockets
[ ] U1: 28 pin socket
Match the notch on the socket
to the notch on the PCB
[ ] L1: Ferrite Bead
Sockets have bent pins to help hold
them against the board. Press in
carefully and solder on reverse side.
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Assembly 4 of 6: DC/DC Converter, 6 pin header, Crystal
Use fine gauge solder unless
otherwise instructed in this document
[ ] U4: DC/DC Converter
[ ]JP1: 6pin Header
[ ] Q1: 16MHz Crystal
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Assembly 5 of 6: MOSFET, Polarized Capacitors, LEDs
Use fine gauge solder unless
otherwise instructed in this document
[ ] Q2: MOSFET
[ ] C5: 4.7uF Tantalum Capacitor
[ ] C9: 100uF Aluminum Electrolytic Capacitor
[ ] DMX: Green 3mm LED
[ ] PWR: Red 3mmLED
Leave the LED sticking up
approximately 3/4” off the board
Longer leg goes by the “+” mark for LEDs and Capacitors
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Assembly 6 of 6: XLR Jack, Modular Jack, USB Jack
Use fine gauge solder unless
otherwise instructed in this document
[ ] X3: XLR Female Jack
[ ] X1: USB-B Connector
Be sure to insert the wiring pins
before snapping jacks into place
[ ]J1: Modular Jack
Board Assembly Complete
Install Optocoupler in OPT1 Socket
Install RS485 Processor in U3 Socket
Install Processor in U1
(Match notch or pin 1 dot to notch on silk screening/socket)
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Enclosure Installation
Before installing the completed xDONGLE into the enclosure bend the red and green LEDs so
they are parallel with the PCB. This will ensure they
slide directly into the enclosure.
Push the completed
xDONGLE PCB into the
enclosure using the last
grove, nearest the bottom.
Push it all the way through
until the XLR and Cat-5 jack
is sticking out. You should
not need to force the PCB
into the enclosure. If it is not going in correctly, check to make sure
the XLR and Cat-5 jacks are matching their holes correctly.
Now that the PCB is installed in the enclosure, simply attach the
four remaining screws for the end plate. Next, use the two included
screws to firmly secure the XLR jack to the end plate. Once all
screws have been installed assembly is now complete.
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Post-Assembly Checks
Use a lighted magnifying glass
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Check all soldering to make sure a proper connection has been made to the circuit board
o If a poor connection has been made, reheat the lead to level the solder
Check for any solder bridges or solder connecting leads.
o Any solder bridges need to be removed before unit is powered on
Ensure LED is oriented correctly
Ensure the correct heat sink is installed on the voltage regulator
Ensure the correct resistors are installed in the correct locations
For safety, ensure the fuse cover is installed on fuse.
Refer to the xDONGLE User Guide for:
Testing the unit
Installing device drivers
Powering the Unit
DO NOT IMMEDIATELY CONNECT THIS DONGLE TO YOUR COMPUTER
UNTIL YOU HAVE READ THE xDongle USER GUIDE!
This manual, as well as the user guide and any other manual for any of our products are available on our
Downloads page at www.seasonalentertainmentllc.com. If you have any questions, please feel free to
contact us via the website.
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