Rocket Kit #1. Illuminated Display Model. Zifnu Electronics LLC.

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1 Rocket Kit #1 Illuminated Display Model Congratulations on your purchase of the Zifnu Rocket Kit #1, an open-source RGB LED illuminated static display model that is intended to provide some insight into wooden model building, electronics, and coding. Zifnu Rocket Kit #1 Features: Open-source model and electronics. Hackable, upgradeable, expandable. Laser-cut & etched Bamboo model. Computer controlled RGB light module. Microchip PIC16F bit microcontroller. Unused microcontroller I/O & USB broken out. ICSP header for updating firmware. 12x prototyping area. 2Mhz 5V DC-DC Boost regulator. Four WS2812B addressable RGB LEDs 38Khz Infrared receiver module. Selectable power source (Battery / USB). 21-key Infrared remote control. Zifnu Electronics LLC Note: This is only a draft of the Zifnu Rocket Kit #1 assembly guide. It is intended that the final version of the guide that ships with the kit will have more detail and information. 1

2 Tools Required for Kit Assembly (not included) Gorilla Gel Super Glue, or other type of glue that works with wood. Avoid non-gel super glues. Optional Items (not included) 220 Grit Sandpaper Wipe-On Poly Painter s or Masking Tape Philips Screwdriver Hobby Knife 2

3 Zifnu Rocket Kit #1 Package Contents LED LENS (x4) 107mm Light Module (x1) 12mm M3 Screw (x4) 5mm M3 Screw (x6) 20mm M3 Hex Standoff (x4) M3 Nut (x6) IR Remote (x1) Rocket Kit #1 Part Sheet 1 (x1) Rocket Kit #1 Part Sheet 2 (x1) 3

4 Zifnu 107mm RGB Light Module Overview The Zifnu 107mm RGB Light Module is a computer controlled light module that is capable of reproducing over 16 million unique colors. The included firmware limits this to a bit over 3000 colors just to simplify the color selection a bit. While the module ships with pre-loaded firmware that allows the module to be used as an accent light, the intent is that you will expand the hardware and software capabilities of the module to suit your own needs and interests. To this end, the module features a 12x spaced prototyping area and additional microcontroller I/O pins, and power supply pins have been broken out via.100 headers. Power and color selection is controlled via the included Infrared remote control. The light module also features an automatic 15 minute shutoff timer to preserve battery life. The module is designed to be powered from Alkaline 4 AA batteries (battery holder included in kit). Alternately, you can add your own power source (e.g. Lithium Polymer pack and charging circuit). The module features an integrated 5 Volt DC-DC Boost Regulator that ensures the LEDs receive the proper voltage even if the source voltage is insufficient, as long as it is at least 2.5 Volts DC and has a sufficient current ratting (>100mAh). Although a USB stack has not been implemented in the current firmware, the USB connections to the microcontroller have been provided via a header, so you can implement your own USB stack for your project if you so wish. The power source selection switch allows you to choose between USB and Battery power sources. Since battery power is the primary power source for the kit, you can also use the power source selection switch as a battery disconnect switch. 4

5 Microcontroller Overview The Zifnu 107mm RGB Light Module has an onboard Microchip PIC16F bit microcontroller that controls the other devices on the PCB. You can consider the microcontroller to be the brains of the operation, anything you instruct the module to do (by pressing a key on the Infrared remote control) is carried out and completed by the microcontroller. A microcontroller is similar to processors like the one in laptops and desktops, the main difference is that the microcontroller has integrated Input/Output peripherals, program memory, random access memory (RAM), and other items that are traditionally external to laptop and desktop processors. Almost every electronic device has a microcontroller in it now days. Coffee makers, watches, cars, and washing machines, just to name a few. The PIC16F1455 microcontroller chosen for the Zifnu 107mm RGB Light Module is capable of running at 48Mhz and executing program instructions at a rate of up to 12 million per second. It also features two 8-bit timer modules, a 16-bit timer module, 10-bit analog-to-digital converter, 5-bit digital-toanalog converter, I2C module, SPI module, USB module, PWM module, complementary waveform generator, integrated temperature module, and more. The unused microcontroller pins and power connections are available for module expansion: The headers located around the microcontroller (pic above and to the right) allow access to the microcontroller pins that are not utilized for functions/features on the Zifnu 107mm RGB Light Module. These can be used to integrate new functions/features of your on design. RA4 Std I/O (input/output), IOC (interrupt on change), AN3 (analog input). RC0 Std I/O (input/output), SCK/SCL (serial clock for SPI/I2C), AN4 (analog input). RC1 Std I/O (input/output), SDA/SDI (serial data for I2C, serial data in for SPI),AN5 (analog input). RC2 Std I/O (input/output), SDO (serial data out for SPI), DAC out 1, AN6 (analog input). RC3 Std I/O (input/output), SS (slave select for SPI), DAC out 2, PWM2 out, AN7 (analog input). USB 2.0 connection header for the integrated USB controller in the PIC16F1455. ICSP In Circuit Serial Programming interface (used to upload new code to the microcontroller*). VCC & GND provides access to power provided by the batteries or USB connector. VREG & GND provided access to output of the DC-DC Boost Regulator circuit. * Note Uploading new code (firmware) to the microcontroller requires a programmer and associated programming software. The Microchip MPLAB-X IDE (integrated development environment) can be downloaded from free of charge. The recommended ICSP programmer is the Microchip PICkit-3 that is available from the same website and through many retailers. 5

6 Infrared Communication Overview The Zifnu 107mm RGB Light Module utilizes an Infrared-based communication system to allow control of the module remotely via the provided 21-key remote control. This is the same familiar technology used for remote controls for TVs, DVD players, Stereos, and other consumer electronic devices. The magic begins when you press a button on a remote control a unique address and command code is transmitted serially to the receiving device using infrared light, which is just above the visual spectrum. The code itself is really just a string of ones and zeros (binary) that the receiving device decodes and then executes a predetermined action associated with the transmitted code. This type of Infrared communication is achieved by the modulation of a carrier wave. The frequency of the carrier wave for the Zifnu 107mm RGB Light Module, and the majority of consumer electronic equipment, is 38Khz. The carrier wave is modulated by simply turning the carrier wave on for a period of time, and then off for a period of time. The timing of the on and off periods are what determines whether a logical one of zero is being transmitted. These timings vary based on what Infrared transmission protocol is being used (NEC, RC5, RC6, Sony, Etc.). The protocols are really just a specification that standardizes the modulation timing and formatting of the data frame that need to be transmitted. The Zifnu 107mm RGB Light Module utilizes the NEC protocol for Infrared communication. In the image to the left you can see an example of the modulation of the 38Khz carrier wave and the timing details for transmitting a logical one or zero to the receiver. In addition to the timing details for the modulation of the carrier wave, Infrared communication protocols also specify the data frame formatting for the data being transmitted. The NEC protocol data frame is preceded by a 9ms-on & 4.5ms-off preamble. The data frame itself contains the 8-bit device address, the inverse of the address, an 8-bit command code, and the inverse of the command code. The transmission of the inverse device code and command code are for redundancy and error checking. One key item worth making note of is the fact that the data is transmitted/received LSB (least significant bit) first. 6

7 DC-DC Boost Converter Overview The Zifnu 107mm RGB Light Module employs a DC-DC Boost Converter circuit to ensure that the WS2812B LEDs and Microcontroller have an optimal, stable supply voltage to operate from. Without the DC-DC Boost Converter circuit, the voltage available to the LEDs and Microcontroller would be limited to the battery voltage level over the life of the battery, which can range from a nominal 3.2VDC 6.0VDC when using four Alkaline AA batteries. If a lithium cell is used the voltage range can drop to a nominal 2.7VDC 4.2VDC range. It is worth noting that the Light Module has a Schottky diode in series with the battery and USB power inputs and provides reverse-polarity protection, but also reduces the input voltage by another VDC. When you consider that the WS2812B LEDs prefer a constant voltage of about 5VDC, you can see the advantages of having a DC-DC Boost Converter that converts anything below 5VDC to a constant 5VDC output. A DC-DC Boost Converter (also called a step-up converter) is a type of switched-mode power supply that takes and input voltage and converts it to a higher, preset output voltage. At the heart of the Zifnu RGB Light Module s DC-DC Boost Converter is the Microchip/MIcrel MIC2876 Boost regulator IC. The MIC2876 is a compact 2Mhz synchronous boost regulator that features bi-directional load disconnect, automatic bypass mode, soft-start circuitry, and is up to 95% efficient. The bi-directional load disconnect ensures that the load (the WS2812B LEDs) are disconnected from the circuit when the boost regulator is not enabled. This is an important feature considering the control IC in the WS2812B LEDs is running even if the LEDs are off. This power draw would quickly deplete the batteries if the load was not disconnected when the module was in standby (off). The automatic bypass feature of the MIC2876 also saves power by shutting down its internal Boost Converter circuitry when the input voltage is greater than the desired, preset output voltage. 7

8 WS2812b RGB LED Overview The Zifnu 107mm RGB Light Module utilizes four Worldsemi WS2812B individually addressable RGB LEDs. Each WS2812B LED contains a red, green, and blue LED pixel and a control IC that allows each pixel s brightness to be set at 256 distinct levels. By varying the level of each pixel, the WS2812B LED is capable of reproducing unique colors. A custom one-wire serial communication protocol is used to send commands to the integrated control IC, and therefore control the brightness level of the individual elements. The WS2812B LEDs are packaged in a standard 5050 case and have four leads, VDD (+5 VDC), VSS (ground), DIN (data in), and DOUT (data out). Multiple LEDS can be daisy-chained by connecting DOUT from the first LED to DIN on the next LED, and so forth. When transmitting serial data to the daisy-chained LEDs, the first 24 bits of data (red, green, blue levels) are accepted by the first LED in the chain, additional data is retransmitted to the next LED in the chain which accepts the first 24 bits of the data and retransmits the next 24 bits to the next LED, and so forth. Serial communication with the WS2812B LEDs is accomplished by varying the time that the data line is high (5V) versus a low state (0v). A logical zero is transmitted via a 0.4us high and 0.85us low pulse. A logical one is transmitted via a 0.8us high and 0.45us low pulse. Using this format, 24 bits are transmitted to the LED (8 bits for the red level, 8 bits for the green level, and 8 bits for the blue level). Then next 24 bits of data are retransmitted to the next LED in the chain. Once data has been transmitted to all LEDs in the chain a Reset command is sent to all LEDS in the chain by holding the data line low for 50us or longer. The Reset command instructs the LEDs to display the color that was just communicated to them just prior to the Reset. 8

9 Model Assembly Instructions Page 1 Step 1A Lightly sand the part sheets (Optional) Lightly sand the part sheets with 220 grit sandpaper to remove any loose strands of Bamboo. For best results, always sand in the direction of the wood grain and use very light pressure. It should only take 2-3 passes to remove the loose Bamboo strands. Note: Bamboo is a natural material that, like any other wood, is subject to slight variances in thickness, minor warping, and loose strands. Sanding the material will remove the majority of loose strands that could result in slivers while you are assembling the kit. Applying a finish further reduces these loose strands (See Step 1B below). Step 1B Apply a finish to the part sheets (Optional) Apply a finish to the Bamboo to reduce splintering, protect the wood surface, and provide a richer-look to the material. We recommend using a wipe-on poly finish like the one offered by Minwax. For best results,, lightly sand the part sheets prior to applying a finish, and in-between each coat of the rub-on poly finish. Apply a minimum of three thin coats of the wipe-on-poly finish. 9

10 Model Assembly Instructions Page 2 Step 2 Remove the parts from the part sheets The parts are attached to the part sheets by small break-away connection points that are roughly 1mm in thickness. While you can easily twist the parts to remove them from the sheets, it is recommended that you use a sharp hobby knife to cut the connection points. To do this, simply cut half way through the connection point on one side of the part sheet, and then flip the part sheet over and repeat on the opposite side. While cutting the connection point on the revers side you should hear a small snap, this is the part breaking loose from the part sheet. Once all connection points for a part are cut, the part should be easily removable from the part sheet. Note 1: The Launchpad features four small wooden circles that have a laser-etched lens look to them, if you are building this kit as the table lamp or CCFL lamp you should leave these in place. You can add a bit of glue to the underside to ensure these stay in place. Note 2: The following specifies the rings to use for the standard and optional kit builds. Option ring 1B & 10B reduces the center hole to properly fit a 3/8 IPS lamp tube to help keep the rocket centered. Option ring 3B combines the ring with the Launchpad gantry that locks the rocket to the Launchpad when assembled (to add stability and structural integrity). Standard LED Module Build: Rings 1,2,3,4,5,6,7,8,9,10 Table Lamp Build: Rings 1B,2,3B,4,5,6,7,8,9,10B CCFL Lamp Build: 1B,2,3 OR 3B,4,5,6,7,8,9,10B (Use 3B if you want to secure rocket to Launchpad) Note 3: After removing the parts from the part sheets you may notice that on the parts where the connection points were the wood does not have the classic laser-cut look to the edges (burnt edges where the laser removed the material during cutting). If desired, you can make the appearance more uniform by using a soldering iron on high temp to lightly burn the edge where the connection point was. 10

11 Model Assembly Instructions Page 3 Step 3: Assemble the Launchpad Base You ll need the five Launchpad base parts, glue, and some tape (optional). To ensure that the Launchpad is square when you glue it together it is best to assemble 3 sides of the Launchpad to the top with tape. Once taped together, install the remaining piece with glue and either hold in place until the glue sets, or tape into place. For best results, apply a small amount of glue to the notches. Note 1: Be sure that when you assemble the launchpad the piece with the Zifnu logo and IR receiver hole is in the front, and the piece with the cord cutout and Zifnu Rocket Kit #1 text is in the back. The top plate of the base has three additional holes along the backside edge. Once the first piece is glued into place, remove one of the taped pieces and then glue it into place, once again holding in place until the glue sets or tape into place. Repeat the above step for the remaining pieces. Note 2: Depending on the size of the applicator tip for your glue bottle, you may need to use an alternate applicator (brush, toothpick, etc.). Note 3: For extra strength, after all pieces are glued into place, apply a bead of glue to all inside edges of the Launchpad base. 11

12 Model Assembly Instructions Page 4 Step 4 Assemble the Rocket Step 4A. Sort the rings by number (1-10) and lay them out next to one of the uprights with the fin. Step 4B. Glue in each of the rings in order using a small amount of glue applied to the mating notch on the upright. It is a good idea to use the notch on the ring that is just to the left of the number so you can still view the numbers (in case you need to verify you have them in the right order). Ensure that each ring is square and level. Use the optional rings (1B, 3B, 10B) where applicable. Step 4C. Glue in two of the uprights without fins, one on each side of the upright with fin that you glued in place in step4b. Step 4D. Glue in the remaining fins using the same method in the above steps. Alternate between the uprights with fins and the uprights without fins. When you glue in the uprights with fins it is a good idea to use two edges of the Launchpad base we assembled in Step 3 as a 90 degree square to ensure that the fins are at 90 degrees to each other. Step 4E. Assemble the Nosecone and Engine and insert tem into the top and bottom of the rocket, respectively. These can be glued, or just inserted into place. 12

13 Model Assembly Instructions Page 5 Step 5 Assemble Launchpad Tower Support and Gantry Step 5A. Glue the support brace to the Launchpad Tower with a small amount of glue in each of the notches of the support brace. Hold or tape until the glue is set. Note: if the main tower upright is bowed, install the support brace on the concave side. This will help to straighten the main tower upright. Step 5B. Glue the Gantry to the Launchpad Tower assembly from Step 5A. Use a square or the Launchpad base as a reference to ensure that the Gantry is 90 degrees to the Tower (as shown in image below). 13

14 Model Assembly Instructions Page 6 Step 6 Attach Launchpad Tower Assembly to Launchpad Base Step 6A. Place the Launchpad base on a flat, level surface. Step 6B. Center the rocket model on the Launchpad (you can use the screw holes as reference points). Step 6C. Apply glue to the notches on the bottom of the Launchpad Tower assembly and insert into the mating holes on the Launchpad base. Align the tower so that the Gantry is about 1-2mm away from touching ring 3 of the rocket model. Allow glue to set before moving on to the next step. 14

15 Model Assembly Instructions Page 8 Step 8 Install 107mm RGB Light Module PCB into Launchpad Step 8A. Install 4 AA batteries into the 107mm RGB Light Module and ensure the power switch is set to BAT and then test the unit using the remote. If the module works as anticipated, move on to Step 8B. If you experience any issues, see the troubleshooting section of this manual for help. Step 8B. Install the four 12mm M3 screws and four M3 nuts. Push the screws through the holes on the top side of the Launchpad base and install the nuts on the bottom side. Finger tighten the nuts and then tighten an additional 1/4 turn using a Philips screwdriver. Be careful to not over tighten the screws. Step 8C. Install LED lenses. Hold the PCB with the top side facing up (the side with the LEDs is the top side). Place each of the LED lenses on the PCB so that they cover the LEDs and the alignment pegs on the bottom of the lenses fit into the alignment holes on the PCB. Step 8D. Install PCB into Launchpad base. Hold the Launchpad in one hand and the PCB with lenses in the other. Keep the PCB level and raise it into the Launchpad carefully and ensure the four mounting holes of the PCB align with the four screws that were installed as part of Step 8A. Once the PCB is in place, turn the Launchpad over while holding the PCB firmly in place. Install the four 20mm M# hex standoffs (one at each corner just finger tighten) to secure the PCB in place. Then install the four 5mm M3 screws into the bottom of the four hex standoffs. These 5mm screws should be just finger tight. They serve as a way to level the Launchpad if it is uneven or is placed on an uneven surface. Once the PCB is installed in the Launchpad base, adjust the position of the Infrared sensor so that the dome on the front of the sensor is aligned with the hole in the front of the Launchpad. 15

16 Zifnu 107mm RGB Light Module Troubleshooting If you experience any issues with the light module, try the steps below to correct the issue. 1. If the light module does not turn on: I. Check that the power switch is set to BAT. II. Check that the batteries in the module and the remote are good (use new batteries if in doubt) and that they are installed in the correct orientation. III. The battery holder on the light module grips the batteries tightly, in some cases this can cause the battery terminals to not make contact with the battery holder terminals. Ensure that the batteries are making contact with the terminals. 2. If the light output is inconsistent (flickering or incorrect colors): I. Check that the batteries in the light module are good (use new batteries if in doubt). Low battery voltage can cause the module to flicker, and does not provide an adequate supply voltage to power the individual LED elements as required to reproduce some colors. Note: In some instances the module will work correctly for a while and then the light will flicker or the light color will be incorrect, this is an indicator that the batteries are getting weak and should be replaced. 16

17 Schematic: 17

18 Notes: - Page intentionally left blank for you to use for notes - 18

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