Mark V Parts List & Assembly Steps

Google Drive with pictures of first build

A summary of orders placed but not yet arrived. Include links to emails if they're shareable.

Ideally, when one places an email order to Don (donald_dawson@byu.edu or dawson@ee.byu.edu) or Joe (joseph_bussio@byu.edu), one should CC everyone else on the Monitor team when something has been ordered.

Don and Joe should reply with a confirmation email when they've submitted it. Check with them in person if they haven't replied within two days.

Clear items/orders as they're received.

Digikey ship duration:

• 9 Nov 2016 arrived 15 Nov 2016
• 14 Nov 2016 arrived 16 Nov 2016
• 14 Nov 2016 arrived 18 Nov 2016

ebay for Power Supplies: 14 Nov 2016 arrived 17 Nov 2016

Delvie's Plastics: 14 Nov 2016 arrived 17 Nov 2016

NOTE: Delvie's Plastics is 45 minutes away in 133 West Haven Ave., Salt Lake City, UT, 84115, US. Contact Info: 800-533-5843 / sales@delviesplastics.com A member of the research group could pick them up locally. Otherwise, shipping to Provo is about $12, which costs less to drive there in terms of fuel and hourly rates.

* for boards before the 28mar2017 revision, use 2 discrete Schottky diodes and no diode array

Note: the listed galvanometer is preferred over this alternative galvanometer because it includes a +/-24V power supply, which could be used to power the polygon motor as well. The alternative includes a +/-15V power supply, which isn't enough to power the polygon motor.

SMA ports / adapters should be bought from AliExpress if a 2-week delay is acceptable. If they are needed in a hurry, buy from DigiKey.

The following is for one +30 dBm RF chain:

Note: MiniCircuits ROS-535 is $16 each; DigiKey's VCOs start around $23

The chassis is built out of 7 panels of 1/8” black acrylic sheets, and 3 panels of 1/4“ black acrylic sheets, with a 1/8” aligner panel. They connect together using interdigitating edges, machine screws, and nuts. For the center 1/4“ panel (the optics deck), use square 1/4” nuts so that the aligner panel will lay flat.

Side plates:              4 of 1/8" @ 8.25" x 10.125"
Front/back plates:        3 of 1/8" @ 4.25" x 10.125"
Bottom/middle/top plates: 4 of 1/4" @ 8.25" x 10.125"

You have to be trained and get card access to use the Mechanical Engineering laser cutter in B-34 (that garage-building between the Fletcher and Crabtree). Here's what you do:

1. Register for the YTrain course here, and complete it.
2. Go to the ME Office with some way to show them that you did the training.
3. Tell them you're trying to get access to the Laser Cutter. You'll have to fill out a form and have it signed by the secretaries (helps if you go while they're there).
4. They'll tell you to take that form to the Dean's Office, drop it off, and and a couple of days later you'll have card access to the south door of B-34 (facing the Clyde Building's parking lot).

Book time for the Laser Cutter here. There's more about the Cutter and the ME Dept.'s other machines on their website.

Chassis files for laser cutting are under ~Monitor Development\Chassis Parts New Acrylic Monitor\ Using the ME Laser Cutter, directly cut the files in ~Monitor Development\Chassis Parts New Acrylic Monitor\CorelDraw Cut File\

Layout for 2'x2' 1/8“ panel:

If using ECEn Shop laser cutter, email laser cutout files with maximum cutout dimensions to ecenshop@gmail.com and specify which cutouts go onto which thickness of acrylic. Deliver the acrylic sheets to the ECEn shop.

We will often receive equipment that uses mains voltage (120V-240V) that has varying color codes. This Wikipedia article describes the color codes used around the world. We typically deal with North American and European/Chinese color codes:

We also use standard C13 power cables / C14 power inlets. The Wikipedia page on IEC 60320 is a fun read.

We use to buy separate power inlets / fuse holders / switches, but now we just use an integrated block instead to save time and be safer:

NOTE: In the above schematic, the fuse is the closest component to the Live pin in the Line-in port. This is so that if the fuse blows, only half of the fuse holder is still energized, and nothing else in the system. If the fuse was on the Neutral wire and blew, everything would turn off but would still carry the risk of electrocution, because it's still connected to the +/-120VAC live wire.

The various voltage supplies use are the following:

Power Supply Unit:
	ATX PSU	24V PSU	9V DC-DC Converter
Voltage Buses:	+3.3V, +5V, +12V, -12V	+24V	+9V
Max Current:	11A, 12A, 12.7A, 0.5A	1A	2A
Input:	120VAC mains	120VAC mains	+12VDC

The different voltages used by the HoloMonitor are as follows:

*NOTE: +24V and +9V are not part of the ATX standard; they have internal color codes of green and orange (or purple) respectively within the Monitor project.

The Scanner Shield should be built starting with the smallest SMD components working up. The bigger components (installed later) make it difficult to read occluded SMD pads with the soldering iron.

All of these components are available in the Scanner Shield parts box. Some SMD parts are taped onto a partslist paper in this box. Use the schematic and board layout as reference.

READ THE SCANNER SHIELD'S ERRATA BEFORE ASSEMBLY to familiarize yourself with various problems that have to be fixed. Some of the issues may be solved / no longer applicable.

Solder in the SMD components first:

At this point, solder in the -5V regulator patch board (see errata). Even though it's not shown in the below picture.

Use the following resistance values for the various power LEDs:

* not part of ATX voltages / color code
† orange is the color of +3.3V in the ATX code, but nothing we use uses +3.3V

Then solder in the ports, jumpers, and headers: (NOTE: the power port needs a corner to be Dremel'd to fit over C3.)

Then the heatsink, power transistor, and potentiometers:

As with the Scanner Shield, solder in the small components first. The two capacitors are in parallel with each other, so it doesn't matter which one goes in which spot. Make sure that all of the pins for the connectors are soldered well, and that the key notch for the 10-pin header is orineted correctly.

For the SMA connectors, make sure that there's lots of conductor between the socket ground pins and the ground pad. Otherwise, strange, mystical RF problems may occur.

Nothing has to be done to prepare the polygon mirror for use.

The polygon mirror/motor sits on top of a blue rubber mat

One modification needs to be done to allow the tachometer to work. On the back, solder the following via and resistor terminal together: (the yellow wire's insulation is partially melted)

picture of die-saw-cut Al-coated silicon strips

Have one of the modulator / cleanroom people aluminium-coat a regular wafer, and cut it into 3.5mm x 50mm strips. Save the scraps.

Die-saw training - email Matthew Searle and Jim Fraser: matthew.c.searle@gmail.com jfraser96@byu.edu

Break out the original galvo mirror the following way.

PICTURE OF BREAKING OUT ORIGINAL MIRROR

If a galvo-mirror mating device is not available, print one using this STL file: J:\groups\holography\~Monitor Development\~Optics Simulation\galvo mating device double.stl. It is 3.0192” x 0.9098“ x 0.9098”.

Use superglue to attach the strip mirrors back to back. If only scraps are available, use them to stiffen the mirror.

Use epoxy to attach the mirrors to the galvanometer axis.

Attach a small square of double-sided foam tape on the very end to prevent high-frequency feedback.

found in the CAD/OpticsSupplements GitLab, or inJ:\groups\holography\~Monitor Development\Chassis Parts New Acrylic Monitor\supplements

You'll have to make a 8“ Female-Male extension cable to connect the galvo in the optics deck to the driver in the electronics deck. It should be a 1:1 pin mapping. Some galvos actually only use 6 pins, but this extension cable will still work for those. Just make sure the galvo motor makes the same electrical connections as before (ie, cable isn't flipped).

Build the boards necessary to complete the 30dBm Chain in the Mixer-Amplifier Segments page.

Before testing the RF functionality of any board, test for shorts on each trace with continuity checks. A trace is a section of copper connected to one or more components (Ground is the most common trace). Remember that capacitors should appear open, inductors shorted, and resistors below a certain resistance will appear as shorts (but aren't necessarily 0 Ohms).