Assembly Instructions
Version 32 (J. Simmons, 12/13/2016 11:01 am) → Version 33/41 (J. Simmons, 12/22/2016 04:18 pm)
h1. Assembly Instructions
*TODO - Add instructions for attaching to the bike*
{{toc}}
h2. Introduction
Below are the assembly instructions for the v0.3 *Holoseat* controller. This version is built using an "AdaFruit Feather 32u4 Basic Proto":https://www.adafruit.com/product/2771. It also includes a remotely mountable sensor board. You will need to use your soldering skills on this build.
h2. Sensor Board Assembly
h3. Tools - Sensor Board
* Diagonal Cutters
* Wire Strippers
* Needle Nose Pliers
* Soldering Iron
* Punch Down Tool
h3. Materials - Sensor Board
* (1) HS001 - Double-Side Prototype PCB
* (1) HS002 - Category 5e Jack
* (2) HS003 - 750 OHM 1/2W 1% Axial Resistor
* (2) HS004 - OH090U Hall Effect Sensor
* (2) HS005 - Diffused Blue 3mm LED
* Hook up wire
* Solder
h3. Safety Issues - Sensor Board
* Care must be taken when using sharp hand tools to avoid cuts
* Care must be taken when using the soldering iron, the tip is very hot
* Always wear safety glasses while working with soldering irons
* Avoid breathing in the soldering fumes, use a vent or hood if needed to provide adequate ventilation
h3. Product - Sensor Board
(1) Holoseat Sensor Board
h3. Procedure - Sensor Board
# Prepare Sensor/LED sub-assemblies
Repeat this procedure twice to assemble (2) *Sensor/LED sub-assemblies*
## Take (1) *HS004 - OH090U Hall Effect Sensor* and (1) *HS005 - Diffused Blue 3mm LED* from your supplies
!0h090u1-400x302.png!
## Solder the LED's anode (long leg) to pin 3 of the sensor (the data pin) and solder the LED's cathode (short leg) to pin 2 of the sensor (the ground pin) using the following steps
!led-plus-sensor.png!
### Align the LED to it sits on top of the sensor with the long leg next to pin 3 and the short leg next to pin 2
### Wrap the LED's long leg around pin 3 to create a secure physical connection
### Wrap the LED's short leg around pin 2 to create a secure physical connection
### Apply solder to the two joints formed in the steps above to secure the connections between the LED and the sensor
## Cut approximately 40 cm lengths of black, red, and green hook up wire
## Strip both ends of the (3) lengths of hookup wire
## Solder the hookup wire to the ends of the sensor pins (red to pin 1, black to pin 2, and green to pin 3) using the following steps
!led-plus-sensor-and-leads.png!
### Wrap one end of the red hook up wire around pin 1 to create a secure physical connection
### Apply solder to the joint formed in the step above to secure the connections between the red hookup wire and pin 1
### Wrap one end of the black hook up wire around pin 2 to create a secure physical connection
### Apply solder to the joint formed in the step above to secure the connections between the black hookup wire and pin 2
### Wrap one end of the green hook up wire around pin 3 to create a secure physical connection
### Apply solder to the joint formed in the step above to secure the connections between the green hookup wire and pin 3
## Apply sufficient heat shrink to the red and green joints to cover them completely
## Apply sufficient heat shrink to assembly to completely cover the solder joints of all three leads, leaving some overlapping the LED to give it strain releaf
## Apply larger heat shrink to the three leads made from the hookup wire to complete the *Sensor/LED sub-assembly*
# Prepare the *HS002 - Category 5e Jack*
## Cut approximately 20 cm each of the following colors of hookup wire: (2) green, (1) red, (1) black
## Strip one end of each length of hookup wire
## Use a punch down tool to connect the hookup wires to their corresponding positions on the *HS002 - Category 5e Jack* for pinout option A
### Punch down the stripped end of the red hookup wire to Brown wire position of the Cat5e Jack
### Punch down the stripped end of the black hookup wire to Brown/White wire position of the Cat5e Jack
### Punch down the stripped end of a green hookup wire to Green wire position of the Cat5e Jack
### Punch down the stripped end of the other green hookup wire to Blue/White wire position of the Cat5e Jack
!cat5e-jack-with-leads.png!
# Finish Assembling the Sensor Board
Reference the image below for the following steps
!sensor-board.png!
## Connect the black leads
### Test fit the black leads from both *Sensor/LED sub-assemblies* and the *HS002 - Category 5e Jack*, cutting the wires to length as necessary (remember to leave room for the stripped wire)
### Strip the three black wires from the step above
### Position the three black wires above in the correct holes of the *HS001 - Double-Side Prototype PCB* and bend them over to create a secure physical connection
### Apply solder to the joint formed in the step above to secure the connection among the three black leads
## Connect the red leads
### Take the (2) *HS003 - 750 OHM 1/2W 1% Axial Resistors* and position them according to the diagram (making sure to bend their leads to secure them in place
### Test fit the red leads from both *Sensor/LED sub-assemblies* and the *HS002 - Category 5e Jack*, cutting the wires to length as necessary (remember to leave room for the stripped wire)
### Strip the three red wires from the step above
### Position the three red wires above in the correct holes of the *HS001 - Double-Side Prototype PCB* and bend them over to create a secure physical connection
### Cut a short length of red hookup wire to bridge the red leads according to the diagram
### Strip both ends of this additional length of red wire and place it according to the diagram, bending its ends over to create a secure physical connection
### Apply solder to the joint formed in the step above to secure the connection among the three red leads
## Connect each of the green leads
Repeat these steps for each of the sensors' green leads according to the diagram
### Test fit the green leads from one of the *Sensor/LED sub-assemblies* and the *HS002 - Category 5e Jack*, cutting the wires to length as necessary (remember to leave room for the stripped wire)
### Strip the two green wires from the step above
### Position the two green wires above in the correct holes of the *HS001 - Double-Side Prototype PCB* and bend them over to create a secure physical connection
### Apply solder to the joint formed in the step above to secure the connection among the two green leads
## Cap the *HS002 - Category 5e Jack*
The Sensor Board is now complete.
h2. Controller Assembly
h3. Tools- Controller
* Diagonal Cutters
* Wire Strippers
* Needle Nose Pliers
* Soldering Iron
* Punch Down Tool
h3. Materials- Controller
* (1) HS002 - Category 5e Jack
* (1) HS007 - Adafruit Feather 32u4 Basic Proto
* (1) HS008 - 16mm Illuminated Pushbutton - Green Momentary
* (1) HS011 - 220 ohm 1/2W 5% Carbon Film Resistor
* Hook up wire
* Solder
h3. Safety Issues- Controller
* Care must be taken when using sharp hand tools to avoid cuts
* Care must be taken when using the soldering iron, the tip is very hot
* Always wear safety glasses while working with soldering irons
* Avoid breathing in the soldering fumes, use a vent or hood if needed to provide adequate ventilation
h3. Product- Controller
(1) Holoseat Controller
h3. Procedure- Controller
# Connect the *HS008 - 16mm Illuminated Pushbutton - Green Momentary*
## Prepare the *HS008 - 16mm Illuminated Pushbutton - Green Momentary*
### Cut approximately 20 cm each of the following colors of hookup wire: (1) green, (1) red, (2) black
### Strip both ends of all (5) lengths of hookup wire
### Physically connect one end of the black hookup wire to the (-) terminal of the *HS008 - 16mm Illuminated Pushbutton - Green Momentary* (this is the negative terminal of the embedded LED)
### Solder this joint to complete the connection
### Physically connect one end of a green hookup wire to the (+) terminal of the *HS008 - 16mm Illuminated Pushbutton - Green Momentary* (this is the positive terminal of the embedded LED)
### Solder this joint to complete the connection
### Physically connect one end of the black hookup wire to one of the remaining terminals of the *HS008 - 16mm Illuminated Pushbutton - Green Momentary* (this is one of the leads for the switch)
### Solder this joint to complete the connection
### Physically connect one end of the red hookup wire to one of the remaining terminals of the *HS008 - 16mm Illuminated Pushbutton - Green Momentary* (this is one of the leads for the switch)
### Solder this joint to complete the connection
## Connect the LED portion of the *HS008 - 16mm Illuminated Pushbutton - Green Momentary*
### Take (1) *HS011 - 220 ohm 1/2W 5% Carbon Film Resistor* and place it in the proto area of the *HS007 - Adafruit Feather 32u4 Basic Proto*, with one pin through a Ground hole and the other toward an edge of the proto area
### Solder these joints to complete the connection
### Take the black hookup wire connected to the (-) terminal of the *HS008 - 16mm Illuminated Pushbutton - Green Momentary* and put it through a hole next in the proto field next to the *HS011 - 220 ohm 1/2W 5% Carbon Film Resistor*
### Take the green hook up wire connected to the (+) terminal of the *HS008 - 16mm Illuminated Pushbutton - Green Momentary* and put it through the hole for pin 13 on the *HS007 - Adafruit Feather 32u4 Basic Proto*
### Solder these joints to complete the connection, making sure to bridge the black wire to the *HS011 - 220 ohm 1/2W 5% Carbon Film Resistor*
!led-on-feather.png!
## Connect the switch portion of the *HS008 - 16mm Illuminated Pushbutton - Green Momentary*
### Insert the red hookup wire from the *HS008 - 16mm Illuminated Pushbutton - Green Momentary* into pin 10 (we will be using the built in pullup resistor, so we can simplify the wiring)
### Insert the remaining black hookup wire into a ground hole
### Solder these joints to complete the connection
!switch-connected-to-feather.png!
# Prepare the *HS002 - Category 5e Jack*
## Cut approximately 20 cm each of the following colors of hookup wire: (2) green, (1) red, (1) black
## Strip one end of each length of hookup wire
## Use a punch down tool to connect the hookup wires to their corresponding positions on the *HS002 - Category 5e Jack* for pinout option A
### Punch down the stripped end of the red hookup wire to Brown wire position of the Cat5e Jack
### Punch down the stripped end of the black hookup wire to Brown/White wire position of the Cat5e Jack
### Punch down the stripped end of a green hookup wire to Green wire position of the Cat5e Jack
### Punch down the stripped end of the other green hookup wire to Blue/White wire position of the Cat5e Jack
!cat5e-jack2-with-leads.png!
# Connect the *HS002 - Category 5e Jack*
## Insert the black hookup wire from the *HS002 - Category 5e Jack* into a ground hole
## Solder this joint to complete the connection
## Insert the red hookup wire from the *HS002 - Category 5e Jack* into USB hole
## Solder this joint to complete the connection
## Insert the green hookup wire connected to the Blue/White connection from the *HS002 - Category 5e Jack* into a pin 3
## Solder this joint to complete the connection
## Insert the other green hookup wire from the *HS002 - Category 5e Jack* into pin 2
## Solder this joint to complete the connection
## Cap the *HS002 - Category 5e Jack*
!completed-controller.png!
The Controller is now complete.
h2. Holoseat Final Assembly
h3. Tools - Holoseat
* none
h3. Materials - Holoseat
* (1) Holoseat Sensor Board
* (1) Holoseat Controller
* (1) Exercise pedals (e.g *"DeskCycle":https://www.amazon.com/DeskCycle-Exercise-Pedal-Exerciser-White/dp/B00B1VDNQA/* or *"FitDesk":https://www.amazon.com/FitDesk-Under-Desk-Elliptical/dp/B00Y1FRULM/* )
* (1) HS010 - 3/8 in dia. x 1/8 in thick magnet
* Cloth Tape (Gaf, duct, or similar)
h3. Safety Issues - Holoseat
* none
h3. Product - Holoseat
(1) Completed Holoseat Sensor Board
h3. Procedure - Sensor Board
# start here
*TODO - Add instructions for attaching to the bike*
{{toc}}
h2. Introduction
Below are the assembly instructions for the v0.3 *Holoseat* controller. This version is built using an "AdaFruit Feather 32u4 Basic Proto":https://www.adafruit.com/product/2771. It also includes a remotely mountable sensor board. You will need to use your soldering skills on this build.
h2. Sensor Board Assembly
h3. Tools - Sensor Board
* Diagonal Cutters
* Wire Strippers
* Needle Nose Pliers
* Soldering Iron
* Punch Down Tool
h3. Materials - Sensor Board
* (1) HS001 - Double-Side Prototype PCB
* (1) HS002 - Category 5e Jack
* (2) HS003 - 750 OHM 1/2W 1% Axial Resistor
* (2) HS004 - OH090U Hall Effect Sensor
* (2) HS005 - Diffused Blue 3mm LED
* Hook up wire
* Solder
h3. Safety Issues - Sensor Board
* Care must be taken when using sharp hand tools to avoid cuts
* Care must be taken when using the soldering iron, the tip is very hot
* Always wear safety glasses while working with soldering irons
* Avoid breathing in the soldering fumes, use a vent or hood if needed to provide adequate ventilation
h3. Product - Sensor Board
(1) Holoseat Sensor Board
h3. Procedure - Sensor Board
# Prepare Sensor/LED sub-assemblies
Repeat this procedure twice to assemble (2) *Sensor/LED sub-assemblies*
## Take (1) *HS004 - OH090U Hall Effect Sensor* and (1) *HS005 - Diffused Blue 3mm LED* from your supplies
!0h090u1-400x302.png!
## Solder the LED's anode (long leg) to pin 3 of the sensor (the data pin) and solder the LED's cathode (short leg) to pin 2 of the sensor (the ground pin) using the following steps
!led-plus-sensor.png!
### Align the LED to it sits on top of the sensor with the long leg next to pin 3 and the short leg next to pin 2
### Wrap the LED's long leg around pin 3 to create a secure physical connection
### Wrap the LED's short leg around pin 2 to create a secure physical connection
### Apply solder to the two joints formed in the steps above to secure the connections between the LED and the sensor
## Cut approximately 40 cm lengths of black, red, and green hook up wire
## Strip both ends of the (3) lengths of hookup wire
## Solder the hookup wire to the ends of the sensor pins (red to pin 1, black to pin 2, and green to pin 3) using the following steps
!led-plus-sensor-and-leads.png!
### Wrap one end of the red hook up wire around pin 1 to create a secure physical connection
### Apply solder to the joint formed in the step above to secure the connections between the red hookup wire and pin 1
### Wrap one end of the black hook up wire around pin 2 to create a secure physical connection
### Apply solder to the joint formed in the step above to secure the connections between the black hookup wire and pin 2
### Wrap one end of the green hook up wire around pin 3 to create a secure physical connection
### Apply solder to the joint formed in the step above to secure the connections between the green hookup wire and pin 3
## Apply sufficient heat shrink to the red and green joints to cover them completely
## Apply sufficient heat shrink to assembly to completely cover the solder joints of all three leads, leaving some overlapping the LED to give it strain releaf
## Apply larger heat shrink to the three leads made from the hookup wire to complete the *Sensor/LED sub-assembly*
# Prepare the *HS002 - Category 5e Jack*
## Cut approximately 20 cm each of the following colors of hookup wire: (2) green, (1) red, (1) black
## Strip one end of each length of hookup wire
## Use a punch down tool to connect the hookup wires to their corresponding positions on the *HS002 - Category 5e Jack* for pinout option A
### Punch down the stripped end of the red hookup wire to Brown wire position of the Cat5e Jack
### Punch down the stripped end of the black hookup wire to Brown/White wire position of the Cat5e Jack
### Punch down the stripped end of a green hookup wire to Green wire position of the Cat5e Jack
### Punch down the stripped end of the other green hookup wire to Blue/White wire position of the Cat5e Jack
!cat5e-jack-with-leads.png!
# Finish Assembling the Sensor Board
Reference the image below for the following steps
!sensor-board.png!
## Connect the black leads
### Test fit the black leads from both *Sensor/LED sub-assemblies* and the *HS002 - Category 5e Jack*, cutting the wires to length as necessary (remember to leave room for the stripped wire)
### Strip the three black wires from the step above
### Position the three black wires above in the correct holes of the *HS001 - Double-Side Prototype PCB* and bend them over to create a secure physical connection
### Apply solder to the joint formed in the step above to secure the connection among the three black leads
## Connect the red leads
### Take the (2) *HS003 - 750 OHM 1/2W 1% Axial Resistors* and position them according to the diagram (making sure to bend their leads to secure them in place
### Test fit the red leads from both *Sensor/LED sub-assemblies* and the *HS002 - Category 5e Jack*, cutting the wires to length as necessary (remember to leave room for the stripped wire)
### Strip the three red wires from the step above
### Position the three red wires above in the correct holes of the *HS001 - Double-Side Prototype PCB* and bend them over to create a secure physical connection
### Cut a short length of red hookup wire to bridge the red leads according to the diagram
### Strip both ends of this additional length of red wire and place it according to the diagram, bending its ends over to create a secure physical connection
### Apply solder to the joint formed in the step above to secure the connection among the three red leads
## Connect each of the green leads
Repeat these steps for each of the sensors' green leads according to the diagram
### Test fit the green leads from one of the *Sensor/LED sub-assemblies* and the *HS002 - Category 5e Jack*, cutting the wires to length as necessary (remember to leave room for the stripped wire)
### Strip the two green wires from the step above
### Position the two green wires above in the correct holes of the *HS001 - Double-Side Prototype PCB* and bend them over to create a secure physical connection
### Apply solder to the joint formed in the step above to secure the connection among the two green leads
## Cap the *HS002 - Category 5e Jack*
The Sensor Board is now complete.
h2. Controller Assembly
h3. Tools- Controller
* Diagonal Cutters
* Wire Strippers
* Needle Nose Pliers
* Soldering Iron
* Punch Down Tool
h3. Materials- Controller
* (1) HS002 - Category 5e Jack
* (1) HS007 - Adafruit Feather 32u4 Basic Proto
* (1) HS008 - 16mm Illuminated Pushbutton - Green Momentary
* (1) HS011 - 220 ohm 1/2W 5% Carbon Film Resistor
* Hook up wire
* Solder
h3. Safety Issues- Controller
* Care must be taken when using sharp hand tools to avoid cuts
* Care must be taken when using the soldering iron, the tip is very hot
* Always wear safety glasses while working with soldering irons
* Avoid breathing in the soldering fumes, use a vent or hood if needed to provide adequate ventilation
h3. Product- Controller
(1) Holoseat Controller
h3. Procedure- Controller
# Connect the *HS008 - 16mm Illuminated Pushbutton - Green Momentary*
## Prepare the *HS008 - 16mm Illuminated Pushbutton - Green Momentary*
### Cut approximately 20 cm each of the following colors of hookup wire: (1) green, (1) red, (2) black
### Strip both ends of all (5) lengths of hookup wire
### Physically connect one end of the black hookup wire to the (-) terminal of the *HS008 - 16mm Illuminated Pushbutton - Green Momentary* (this is the negative terminal of the embedded LED)
### Solder this joint to complete the connection
### Physically connect one end of a green hookup wire to the (+) terminal of the *HS008 - 16mm Illuminated Pushbutton - Green Momentary* (this is the positive terminal of the embedded LED)
### Solder this joint to complete the connection
### Physically connect one end of the black hookup wire to one of the remaining terminals of the *HS008 - 16mm Illuminated Pushbutton - Green Momentary* (this is one of the leads for the switch)
### Solder this joint to complete the connection
### Physically connect one end of the red hookup wire to one of the remaining terminals of the *HS008 - 16mm Illuminated Pushbutton - Green Momentary* (this is one of the leads for the switch)
### Solder this joint to complete the connection
## Connect the LED portion of the *HS008 - 16mm Illuminated Pushbutton - Green Momentary*
### Take (1) *HS011 - 220 ohm 1/2W 5% Carbon Film Resistor* and place it in the proto area of the *HS007 - Adafruit Feather 32u4 Basic Proto*, with one pin through a Ground hole and the other toward an edge of the proto area
### Solder these joints to complete the connection
### Take the black hookup wire connected to the (-) terminal of the *HS008 - 16mm Illuminated Pushbutton - Green Momentary* and put it through a hole next in the proto field next to the *HS011 - 220 ohm 1/2W 5% Carbon Film Resistor*
### Take the green hook up wire connected to the (+) terminal of the *HS008 - 16mm Illuminated Pushbutton - Green Momentary* and put it through the hole for pin 13 on the *HS007 - Adafruit Feather 32u4 Basic Proto*
### Solder these joints to complete the connection, making sure to bridge the black wire to the *HS011 - 220 ohm 1/2W 5% Carbon Film Resistor*
!led-on-feather.png!
## Connect the switch portion of the *HS008 - 16mm Illuminated Pushbutton - Green Momentary*
### Insert the red hookup wire from the *HS008 - 16mm Illuminated Pushbutton - Green Momentary* into pin 10 (we will be using the built in pullup resistor, so we can simplify the wiring)
### Insert the remaining black hookup wire into a ground hole
### Solder these joints to complete the connection
!switch-connected-to-feather.png!
# Prepare the *HS002 - Category 5e Jack*
## Cut approximately 20 cm each of the following colors of hookup wire: (2) green, (1) red, (1) black
## Strip one end of each length of hookup wire
## Use a punch down tool to connect the hookup wires to their corresponding positions on the *HS002 - Category 5e Jack* for pinout option A
### Punch down the stripped end of the red hookup wire to Brown wire position of the Cat5e Jack
### Punch down the stripped end of the black hookup wire to Brown/White wire position of the Cat5e Jack
### Punch down the stripped end of a green hookup wire to Green wire position of the Cat5e Jack
### Punch down the stripped end of the other green hookup wire to Blue/White wire position of the Cat5e Jack
!cat5e-jack2-with-leads.png!
# Connect the *HS002 - Category 5e Jack*
## Insert the black hookup wire from the *HS002 - Category 5e Jack* into a ground hole
## Solder this joint to complete the connection
## Insert the red hookup wire from the *HS002 - Category 5e Jack* into USB hole
## Solder this joint to complete the connection
## Insert the green hookup wire connected to the Blue/White connection from the *HS002 - Category 5e Jack* into a pin 3
## Solder this joint to complete the connection
## Insert the other green hookup wire from the *HS002 - Category 5e Jack* into pin 2
## Solder this joint to complete the connection
## Cap the *HS002 - Category 5e Jack*
!completed-controller.png!
The Controller is now complete.
h2. Holoseat Final Assembly
h3. Tools - Holoseat
* none
h3. Materials - Holoseat
* (1) Holoseat Sensor Board
* (1) Holoseat Controller
* (1) Exercise pedals (e.g *"DeskCycle":https://www.amazon.com/DeskCycle-Exercise-Pedal-Exerciser-White/dp/B00B1VDNQA/* or *"FitDesk":https://www.amazon.com/FitDesk-Under-Desk-Elliptical/dp/B00Y1FRULM/* )
* (1) HS010 - 3/8 in dia. x 1/8 in thick magnet
* Cloth Tape (Gaf, duct, or similar)
h3. Safety Issues - Holoseat
* none
h3. Product - Holoseat
(1) Completed Holoseat Sensor Board
h3. Procedure - Sensor Board
# start here