HELIX V3 Assembly And Setup Manual

Copyright 2012 Gregory Bartlett
11/10/2014

Helix Light Controller

Helix V3 Main Board

Assembly and Setup Manual

Helix Main Board

Assembly and Setup Manual

Table of Contents

Overview .................................................................................................................................................... 2

Helix Main Board Bill Of Materials (BOM) ................................................................................................... 3

Helix Main BOM Continued .................................................................................................................... 4

Initial Assembly of the Main Board ............................................................................................................. 5

Step-by-Step Instructions (Table 1 of 3) .................................................................................................. 5

Step-by-Step Instructions (Table 2 of 3) .................................................................................................. 6

Step-by-Step Instructions (Table 3 of 3) .................................................................................................. 7

Pictorial Assembly (1 of 7): RTC Crystal and Resistors (Steps 1-13) ......................................................... 8

Pictorial Assembly (2 of 7): Resistors, Diodes, Crystal and Sockets (Steps 14-30) .................................... 9

Pictorial Assembly (3 of 7): LEDs (Steps 31-45) ..................................................................................... 10

Pictorial Assembly (4 of 7): SIP Resistors and Bypass Caps (Steps 46-61) .............................................. 11

Pictorial Assembly (5 of 7): IC Sockets, Switch and MOSFET (Steps 62-73) ............................................ 12

Pictorial Assembly (6 of 7): Headers, MP3 Sockets and Fuse Clips (Steps 74-86) ................................... 13

Pictorial Assembly (7 of 7): Remaining Components (Steps 87-110) ..................................................... 14

Assembly Notes .................................................................................................................................... 15

Assembly Pictures ................................................................................................................................. 17

Initial Power Up of the Main Board ........................................................................................................... 18

Assembly of the MP3 Board...................................................................................................................... 19

Final Assembly of the Main Board............................................................................................................. 20

Final Assembly Steps ............................................................................................................................ 20

Configuration of the MicroSD Card ........................................................................................................... 21

Initial Testing of the Main Board ............................................................................................................... 23

Final Testing of the Helix Network Controller Board.................................................................................. 24

MicroSD Card and MP3 Player Test ....................................................................................................... 24

Test and Setup of the Real Time Clock .................................................................................................. 24

Helix Network Controller Calibration .................................................................................................... 27

Final Testing of the Network Node Board ................................................................................................. 28

XBee Configuration and MicroSD Card Test........................................................................................... 28

Setup of the Helix Main Board .................................................................................................................. 29

Custom Cable Pin-outs ............................................................................................................................. 30

Comments, Questions or Concerns contact the developer at: [e-mail]

1

Helix Main Board

Assembly and Setup Manual

Overview

This is the basic assembly and setup instructions for the Helix Main Board v2. It is not the purpose of this document
to teach soldering techniques or basic electronics. If you need assistance in this area there are several other sources
on the internet for this type of information.

The Helix Main Board can be assembled in two different configurations. The first configuration is as the Helix
Network Controller. There is only one Helix Network Controller in a Helix Network. The Network Controller is
responsible for starting/stopping the show, playing the MP3 songs and providing the synchronization pulses to the
other controllers.

The second configuration is the Helix Network Node. All Helix Main Boards that are not the Helix Network Controller
are Helix Network Nodes. The Network Node doesn’t have the Real Time Clock (RTC) or the MP3 player. In the
assembly notes the parts that are not needed in a Network Node are identified.

The assembly and setup will follow these steps:

1) Initial assembly of the main board

2) Initial power up of the main board

3) Assembly of the MP3 player

4) Final assembly of the main board

5) Configuration of the MicroSD Card

6) Initial testing of the main board

7) Final testing of the Helix Network Controller or Helix Network Node

The Helix Main Board is fairly complicated to assemble. If you have little experience with PCB assembly you may

want to consider assembling the Helix Daughter Board first.

If you have any suggestions or problems with this manual or assembly of the Helix Main Board please
email the developer at: [e-mail]

Comments, Questions or Concerns contact the developer at: [e-mail]

2

Helix Main Board Bill Of Materials (BOM)

Part

Description

Supplier

Part#

Qty

Notes

AJ1

3.5 mm Vertical Jack

Mouser

161-0352-EX

1

AJ1 Not needed on HNN

B1

Battery Holder

Mouser

614-VBH2032-1

1

B1 is not needed on Helix
Network Node (HNN)

C1, C2, C3, C4, C5,
C6, C7, C8, C9, C10,
C11

0.1 uF Bypass Cap

Mouser

75-1C10Z5U104M050B

11

C1 and C11 are not
needed on a HNN
C12

33pF Timing Cap

Mouser

80-C323C330K2G

1 C13

4700 uF Filter Cap

Mouser

647-UVZ1C472MHD

1

C14, C15

100 uF Filter Cap

Mouser

647-UVR1E101MED1TD

2

D1, D2, D3, D4, D5

1N5817

Mouser

821-1N5817

5

D3, D4 not needed HNN

D6, D8, D10, D13

RED LED

Mouser

859-LTL42EKEKNN

4

D7, D12, D15, D16,
D17, D18, D19

GREEN LED

Mouser

859-LTL-4236N

7

D9, D11, D14

YELLOW LED

Mouser

859-LTL1CHKYKNN

3

F1

FUSE Horizontal

Mouser

534-3517

2

H1, H2, H3, H4, H7,
H8, H9

0.1" Pin Strip Header 40
Pin

Mouser

517-6111TG

1

H5, H6

0.1" Pin Strip Header 5
Pin

Mouser

517-929834-01-05-RK

1

H5, H6 not needed on
HNN

IC1

DS1337

Mouser

700-DS1337

1

IC1 not needed on HNN

IC2

24LC256

Provided with the PCB

IC3

H11AA1-M

Mouser

512-H11AA1M

1 IC4, IC5, IC6, IC7

SN75174NE4

Mouser

595-SN75174NE4

4

IC8

Propeller

Mouser

619-P8X32A-D40

1 IC9

MCP23016

Mouser

579-MCP23016-I/SP

1 IC10

ST485

Provided with the PCB

J1, J2, J3, J4, J5, J6

RJ45

Mouser

571-5556416-1

6

MP3

MP3 Breakout Board

SparkFun

BOB-09943

1

MP3 not needed on HNN

NE1

NE-2 Neon Lamp

Mouser

606-A9A

1 Q1

TN0702N3-G

Mouser

689-TN0702N3-G

1

Q1 not needed on HNN

R1, R2, R3, R4, R5,
R6, R7

220 ohm Resistor

Mouser

291-220-RC

7

R8

100 ohm Resistor

Mouser

291-100-RC

1 R9, R10

510 ohm Resistor

Mouser

291-510-RC

2 R11, R12

1K ohm Resistor

Mouser

291-1K-RC

2

R13

3.9K ohm Resistor

Mouser

291-3.9K-RC

1

R14, R15, R16, R17,
R18, R19, R20

10K ohm Resistor

Mouser

291-10K-RC

7

R19 not needed on HNN
R21

100K ohm Resistor

Mouser

291-100K-RC

1

330K ohm for 220VAC

RA1

10K ohm SIP Resistor (8)

Mouser

858-L091S103LF

1

RA1 not needed on HNN

RA2

1K ohm SIP Resistor (8)

Mouser

858-L091S102LF

1

RA2 not needed on HNN

RA3

220 ohm SIP Resistor (7)

Mouser

858-L081S221LF

1 RA4

47K ohm SIP Resistor (5)

Mouser

858-L061S473LF

1 S1

MicroSD Socket

Provided with the PCB

SW1

Tactile Switch

Mouser

611-PTS645SL702

1 T1

6.3V 1A Transformer

Mouser

838-3FD-412

1

TB1, TB2, TB3, TB4,
TB5, TB6, TB7, TB8,
TB9

2 POS 5mm Terminal
Block

Mouser

651-1935161 or 571­2828372

9

TB2, TB3, TB4, TB5, TB6,
TB7, TB8 and TB9 not
needed on HNN

U1

5V Regulator

Mouser

511-LD1085V50

1 U2

3.3V Regulator

Mouser

926-LMS1585ACT33NOPB

1 U3

DB101

Mouser

583-DB101

1

XTAL1

32.768KHz Crystal

Mouser

695-CFS206-327KB-U

1

XTAL1 not needed HNN

XTAL2

5MHz Crystal

Mouser

520-HCU500-20X

1

Helix Main Board

Assembly and Setup Manual

Comments, Questions or Concerns contact the developer at: [e-mail]

3

Helix Main Board

Part

Description

Supplier

Part#

Qty

Notes

B1

CR2032 Lithium Coin Cell

Mouser

614-CR2032-MFR

1

B1 not needed on HNN

IC4, IC5, IC6, IC7

16p DIP Socket

Mouser

571-1-2199298-4

4 IC8

40p DIP Socket

Mouser

571-1-2199299-5

1

IC1, IC2, IC10

8p DIP Socket

Mouser

571-1-2199298-2

3

IC1 not needed on HNN

IC3

6p DIP Socket

Mouser

571-1-2199298-1

1 IC9

28p DIP Socket

Mouser

571-1-2199298-9

1

F1

1A 5x20mm Fast Blow
Fuse

Mouser

576-0217001.MXP

1

F1

Fuse Cover

Mouser

534-3527C

1

H1^2, H3, H4, H7,
H8, H9

0.1" Shunt 1A

Mouser

151-8010-E

7

MP3

0.1" PCB Mount Socket
20 Position

Mouser

517-929850-01-20-RB

1

MP3 not needed on HNN
U1, U2

TO-220 Heatsink

Mouser

532-579302B00

2

Recommended Spacers

Mouser

561-KSP117

4

Part

Description

Supplier

Part#

Qty

Notes

RS1

USB to RS485

SparkFun

BOB-09822

1

Not needed on HNN

USB miniB Cable

SparkFun

CAB-00598

1

Not needed on HNN

J7

RJ45

Mouser

571-5556416-1

1

Not needed on HNN

Part

Description

Supplier

Part#

Qty

Notes

RF1

XBEE PRO

Mouser

888-XBP24-AWI-001

2

Only 1 needed on HNN

RF1

2mm Pitch SIP Socket
10p

SparkFun

PRT-08272

2

XBee Explorer USB

SparkFun

WRL-11812

1

Not needed on HNN

USB miniB Cable

SparkFun

CAB-00598

1

Not needed on HNN

Assembly and Setup Manual

Helix Main BOM Continued

Misc Other Parts

USB to RS485 Option

If you plan to use the board in a wired configuration only then you will need one set of the following parts.

XBee Wireless Option

If you plan to use the board in a wireless configuration then you will need one set of the following parts.

If you have any questions about the wired or wireless options please contact the developer at

[e-mail] before you place your order.

Comments, Questions or Concerns contact the developer at: [e-mail]

4

Helix Main Board

Step

Done

Ref Number

Value

Note

1 XTAL1

32.768 KHz

See Note 1; RTC Crystal; Not needed on Network Node

2 R1

220 

Red, Red, Brn

3 R2

220 

Red, Red, Brn

4 R3

220 

Red, Red, Brn

5 R4

220 

Red, Red, Brn

6 R5

220 

Red, Red, Brn

7 R6

220 

Red, Red, Brn

8 R7

220 

Red, Red, Brn

9 R8

100 

Brn, Blk, Brn

10 R9

510 

Grn, Brn, Brn

11 R10

510 

Grn, Brn, Brn

12 R11

1 K

Brn, Blk, Red

13 R12

1 K

Brn, Blk, Red

14 R13

3.9 K

Orn, Wht, Red

15 R14

10 K

Brn, Blk, Orn

16 R15

10 K

Brn, Blk, Orn

17 R16

10 K

Brn, Blk, Orn

18 R17

10 K

Brn, Blk, Orn

19 R18

10 K

Brn, Blk, Orn

20 R19

10 K

Brn, Blk, Orn; Not needed on Network Node

21 R20

10 K

Brn, Blk, Orn

22 R21

100 K

Brn, Blk, Yel

23 D1

1N5817

See Note 2

24 D2

1N5817

See Note 2

25 D3

1N5817

See Note 2; Not needed on Network Node

26 D4

1N5817

See Note 2; Not needed on Network Node

27 D5

1N5817

See Note 2

28 XTAL2

5 MHz

See Note 3; Propeller Chip Crystal

29 U3

DB101

See Note 4

30 RF1 Left Socket

10p SIP Socket

See Note 5; 2mm Pitch

31 RF1 Right Socket

10p SIP Socket

See Note 5; 2mm Pitch

32 D6

Red T-1 (3mm) LED

See Note 6

33 D8

Red T-1 (3mm) LED

See Note 6

34 D10

Red T-1 (3mm) LED

See Note 6

35 D13

Red T-1 (3mm) LED

See Note 6

36 D7

Grn T-1 (3mm) LED

See Note 6

37 D12

Grn T-1 (3mm) LED

See Note 6

38 D15

Grn T-1 (3mm) LED

See Note 6

39 D16

Grn T-1 (3mm) LED

See Note 6

40 D17

Grn T-1 (3mm) LED

See Note 6

Assembly and Setup Manual

Initial Assembly of the Main Board

The initial assembly of the main board will consist of soldering all of the major components to the PCB, starting with
the components that have the lowest profile and finishing with the ones with the highest profile. Two methods of
assembly are presented in this manual. This first is a table with the step-by-step instructions and associated notes.
The second is a series of pictures of the main board’s silk screen with arrows and notes pointing to each step. Each
method shares the same notes and pictures. Use whichever method works best for you.

Step-by-Step Instructions (Table 1 of 3)

Comments, Questions or Concerns contact the developer at: [e-mail]

5

Step-by-Step Instructions (Table 2 of 3)

Step

Done

Ref Number

Value

Note

41 D18

Grn T-1 (3mm) LED

See Note 6

42 D19

Grn T-1 (3mm) LED

See Note 6

43 D9

Yel T-1 (3mm) LED

See Note 6

44 D11

Yel T-1 (3mm) LED

See Note 6

45 D14

Yel T-1 (3mm) LED

See Note 6

46 RA1

10 K SIP Resistor

See Note 7; Not needed on Network Node

47 RA2

1 K SIP Resistor

See Note 7; Not needed on Network Node

48 RA3

220  SIP Resistor

See Note 7

49 RA4

47 K SIP Resistor

See Note 7

50 C1

0.1 F

Not needed on Network Node

51 C2

0.1 F

52 C3

0.1 F

53 C4

0.1 F

54 C5

0.1 F

55 C6

0.1 F

56 C7

0.1 F

57 C8

0.1 F

58 C9

0.1 F

59 C10

0.1 F

60 C11

0.1 F

Not needed on Network Node

61 C12

33 pF

62 IC1 Socket

8p DIP Socket

See Note 8; Not needed on Network Node

63 IC2 Socket

8p DIP Socket

See Note 8

64 IC10 Socket

8p DIP Socket

See Note 8

65 IC3 Socket

6p DIP Socket

See Note 8

66 IC4 Socket

16p DIP Socket

See Note 8

67 IC5 Socket

16p DIP Socket

See Note 8

68 IC6 Socket

16p DIP Socket

See Note 8

69 IC7 Socket

16p DIP Socket

See Note 8

70 IC8 Socket

40p DIP Socket

See Note 8

71 IC9 Socket

28p DIP Socket

See Note 8

72 SW1

Tactile Switch

73 Q1

MOSFET

See Note 9; Not needed on Network Node

74 H1

4p Header

See Note 10

75 H2

4p Header

See Note 10

76 H3

3p Header

See Note 10

77 H4

3p Header

See Note 10

78 H5

3p Header

See Note 11; Not needed on Network Node

79 H6

2p Header

See Note 11; Not needed on Network Node

80 H7

2p Header

See Note 11

81 H8

2p Header

See Note 11

82 H9

2p Header

See Note 11

83 MP3 Left Socket

10p SIP Socket

See Note 12; 0.1” Pitch; Not needed on Network Node

84 MP3 Right Socket

10p SIP Socket

See Note 12; 0.1” Pitch; Not needed on Network Node

85 F1A

Fuse Clip

See Note 13

86 F1B

Fuse Clip

See Note 13

87 TB1

2p Terminal Block

AC Input; 0.2” Pitch

Helix Main Board

Assembly and Setup Manual

Comments, Questions or Concerns contact the developer at: [e-mail]

6

Step-by-Step Instructions (Table 3 of 3)

Step

Done

Ref Number

Value

Note

88 TB2

2p Terminal Block

See Note 14; Not needed on Network Node

89 TB3

2p Terminal Block

See Note 14; Not needed on Network Node

90 TB4

2p Terminal Block

See Note 14; Not needed on Network Node

91 TB5

2p Terminal Block

See Note 14; Not needed on Network Node

92 TB6

2p Terminal Block

See Note 14; Not needed on Network Node

93 TB7

2p Terminal Block

See Note 14; Not needed on Network Node

94 TB8

2p Terminal Block

See Note 14; Not needed on Network Node

95 TB9

2p Terminal Block

See Note 14; Not needed on Network Node

96 C14

100 F

See Note 15

97 C15

100 F

See Note 15

98 J1

RJ45 Jack

Cat 5 Jack

99 J2

RJ45 Jack

Cat 5 Jack

100 J3

RJ45 Jack

Cat 5 Jack

101 J4

RJ45 Jack

Cat 5 Jack

102 J5

RJ45 Jack

Cat 5 Jack

103 J6

RJ45 Jack

Cat 5 Jack

104 AJ1

Audio Jack

Stereo Audio Jack; Not needed on Network Node

105 NE1

Neon Bulb

106 U1

LD1085V50

See Note 16; 5V Regulator

107 U2

AP1084T33L

See Note 16; 3.3V Regulator

108 B1 Socket

Coin Cell Socket

Socket for 3V Coin Cell; Not needed on Network Node

109 C13

4700 F

See Note 15

110 T1

3FD-412

See Note 17; 6.3V Center Tap 1A Transformer

Helix Main Board

Assembly and Setup Manual

Comments, Questions or Concerns contact the developer at: [e-mail]

7

Helix Main Board

Assembly and Setup Manual

Pictorial Assembly (1 of 7): RTC Crystal and Resistors (Steps 1-13)

11 [ ] R10 10 [ ] R9
510  510 
Grn, Brn, Brn Grn, Brn, Brn

7 [ ] R6 9 [ ] R8
220  100 
Red, Red, Brn Brn, Blk, Brn

1 [ ] XTAL1* 8 [ ] R7

32.768 KHz 220 
See Note 1 Red, Red, Brn

4 [ ] R3 13 [ ] R12

220  1 K
Red, Red, Brn Brn, Blk, Red

6 [ ] R5 5 [ ] R4

220  220 
Red, Red, Brn Red, Red, Brn

3 [ ] R2

220 
Red, Red, Brn

2 [ ] R1

220 
Red, Red, Brn

12 [ ] R11

1 K 
Brn, Blk, Red

* These parts are not needed on a Network Node Main Board

Comments, Questions or Concerns contact the developer at: [e-mail]

8

Helix Main Board

Assembly and Setup Manual

Pictorial Assembly (2 of 7): Resistors, Diodes, Crystal and Sockets (Steps 14-30)

26 [ ] D4* 21 [ ] R20 27 [ ] D5 19 [ ] R18
1N5817 10 K 1N5817 10 K
See Note 2 Brn, Blk, Orn See Note 2 Brn, Blk, Orn

14 [ ] R13

3.9 K
Orn, Wht, Red
20 [ ] R19*
10 K
Brn, Blk, Orn

25 [ ] D3* 17 [ ] R16

1N5817 10 K
See Note 2 Brn, Blk, Orn

30 [ ] RF1 L Socket 18 [ ] R17

10p SIP 2mm Pitch 10 K
See Note 5 Brn, Blk, Orn

31 [ ] RF2 R Socket 15 [ ] R14
10p SIP 2mm Pitch 10 K
See Note 5 Brn, Blk, Orn

28[ ] XTAL2
5 MHz
See Note 3

24 [ ] D2
1N5817
See Note 2
16 [ ] R15

10 K           23 [ ] D1
Brn, Blk, Orn 1N5817
See Note 2

29 [ ] U3 22 [ ] R21

DB101 100 K
See Note 4 Brn, Blk, Yel

* These parts are not needed on a Network Node Main Board

Comments, Questions or Concerns contact the developer at: [e-mail]

9