Assembly Instructions For The REN 32

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Disclaimers

The standard disclaimers pertaining to the information contained on this wiki page are listed here.
THIS WIKI PAGE IS NOT COMPLETE YET.

Board Assembly

The following sequence of steps is by no means the only way to assemble the Ren32. It is simply a suggested order of events to achieve the desired goal. You can click on any photo for an enlarged view of that photo.


NOTE: The part numbers referenced in the following instructions are those taken from the REN 32 BOM.



  • 1 - Start by checking the PCB over for any obvious production faults. Check for traces that end abruptly or have cracks/breaks in them. Also check that all holes are clear.
REN32-BOARD-FRONT.jpg REN32-BOARD-BACK.jpg
  • 2 - Install four diodes D1 thru D4 (PN# 625-1N5817-E3). The diodes will have a silver/grey stripe on a black body. Make sure that this stripe lines up with the stripe on the PCB silk screen (to the left).
REN32-POWER-DIODE.jpg REN32-STEP2.jpg
  • 3 - Install two 750 ohm resistors R1 & R2 (PN# 291-750-RC). Make sure that the resistors have a value of 750 ohms (violet/green/brown/gold stripes). These resistors have no polarity to worry about.
REN32-STEP3.jpg
  • 4 - Install the 120 ohm resistor R3 (PN# 291-120-RC). Make sure that the resistor has a value of 120 ohms (brown/red/brown/gold stripes). This resistor have no polarity to worry about.
REN32-STEP4.jpg
  • 5 - Install two 1K ohm resistors R4, R7 (PN# 299-1K-RC). Make sure that the resistors have a value of 1K ohm (brown/black/red/gold stripes). These resistors have no polarity to worry about.
REN32-STEP5.jpg
  • 6 - Install three 27K ohm resistors R5, R8, R9 (PN# 299-27K-RC). Make sure that the resistors have a value of 27K ohms (red/violet/orange/gold stripes). These resistors have no polarity to worry about.
REN32-STEP6.jpg
  • 7 - Install one 680 ohm resistors R6 (PN# 299-680-RC). Make sure that the resistor has a value of 680 ohms (blue/gray/brown/gold stripes). These resistors have no polarity to worry about.
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  • 8 - Install zener diode D5 (PN# 78-1N5229B). The diode must be installed correctly. The diode should have a black stripe on the orange/red body. Make sure that this stripe lines up with the stripe on the PCB silkscreen (to the left).
REN32-SIGNAL-DIODE.jpg REN32-STEP7.jpg
  • 9 - Install zener diode D6 (PN# 78-1N5239B). The diode must be installed correctly. The diode should have a black stripe on the orange/red body. Make sure that this stripe lines up with the stripe on the PCB silkscreen (to the right).
REN32-SIGNAL-DIODE-RIGHT.jpg REN32-STEP8.jpg
  • 10 - Install four 0.1uF capacitors C3, C4, C5 & C6 (PN# 80-C322C104K5R). These capacitors have no polarity to worry about.
REN32-STEP9.jpg
INSTALLATION NOTE:
The following resistor network is a "bussed" type resistor network. This means that the five resistor components (pins 2-6) are all connected in a common buss to pin 1. Installing the resistor network backwards will cause a multitude of malfunctions. So please take the time to make sure it is installed correctly.
REN32-RESISTOR.jpg
  • 11 - Install the 330 ohm resistor network RN1 (PN# 264-330-RC). The resistor network should have a dot on it to indicate pin 1. Insert pin 1 of the resistor network into the square solder pad (to the left).
REN32-STEP10.jpg
  • 12a - Install four green LEDs PWR (D7), HB, ZC & SD (PN# 604-WP710A10GT). The LEDs are polarized and must be installed correctly. The short lead is the cathode and must be placed in the square solder pad.
REN32-STEP11A.jpg
  • 12b - Install two red LEDs FE & OE (PN# 604-WP710A10IT). The LEDs are polarized and must be installed correctly. The short lead is the cathode and must be placed in the square solder pad.
REN32-STEP11B.jpg
  • 13 - Install three 2-pin vertical headers JP1, JP2 & JP3 (PN# 538-22-03-2021). Install the short end through the board. These headers have no polarity to worry about.
REN32-STEP12.jpg
  • 14 - Install the clock oscillator U3 (PN# 815-ACH-18.432-EK). The oscillator must be installed in the correct orientation. The oscillator has three rounded corners and one squared corner, make sure that the squared corner is positioned to match the PCB silkscreen (upper left corner).
REN32-CLOCK.jpg REN32-STEP13.jpg
  • 15 - Install the voltage regulator U1 (PN# 511-LF50CV). The voltage regulator must be installed correctly. The voltage regulators tab/heat sink must be aligned with wider line of the PCB silkscreen outline (facing towards the PCB top edge).
REN32-STEP14.jpg
  • 16 - Install the 2200uF capacitor C1 (PN# 140-REA222M1CBK1320P). This capacitor is polarized and must be installed correctly. The capacitor should have a black stripe on the body to indicate which lead is negative. The positive lead of the capacitor will be the longer lead. Make sure that the positive lead is placed in the square solder pad.
REN32-STEP15.jpg
  • 17 - Install the 47uF capacitor C2 (PN# 140-REA470M1CBK0511P). This capacitor is polarized and must be installed correctly. The capacitor should have a silver/grey stripe on the body to indicate which lead is negative. The positive lead of the capacitor will be the longer lead. Make sure that the positive lead is placed in the square solder pad.
REN32-STEP16.jpg
  • 18 - Install two fuse clips (PN# 534-3517) Note: they are directional for proper fit of the fuse. A helpful installation tip here would be to put a fuse in the clips when you position them in their mounting holes. This will help keep them correctly aligned so that the fuse will fit properly. Examine them carefully, as they often have extra bends that should be placed on the outside end, to stop the fuse from slipping out. Be careful, the fuse holders require a fair amount of solder and heat to attach them. The FUSE should not be present when installing the clips, as the extra heat may melt the end of the fuse.
Fuse Clip.png REN32-STEP17.jpg
INSTALLATION NOTE:
Pin 1 of the following IC sockets must be aligned with the square solder pad. Another way to verify that you installed them correctly is to make sure that the notch on the socket is aligned with the notch on the PCB silkscreen outline.
  • 19 - Install two 8-pin IC sockets for U4 & U5 (PN# 571-1-390261-2). Install with the notch to the right.
REN32-STEP18.jpg
  • 20 - Install four 14-pin IC sockets for U6, U7, U8 & U9 (PN# 571-1-390261-3). Install with the notch to the right.
REN32-STEP19.jpg
  • 21 - Install one 6-pin IC sockets for U2 (PN# 571-1-390261-1). Install with the notch up towards the top of the board.
REN32-STEP20.jpg
  • 22 - Install one terminal blocks for 120V input (PN# 571-7969492). Install with the openings for the wires facing off the edge of the board.
REN32-STEP21.jpg
  • 23 - Install the correct voltage jumper for your voltage. You can use a short piece of 22 ga wire, or you could use a cutoff lead from the diodes. The REN 32 can either be used for 115VAC (common in North America) or 230AC (common in the rest of the world). For use with 115VAC, install the two wire jumpers across the space marked for 115V. For use with 230VAC, install one wire jumper across the space marked for 230V.
REN32-STEP22A.jpg REN32-STEP22B.jpg
  • 24 - Install the transformer TF1 (PN# 838-3FD-412). It is important that you get the correct orientation for the transformer. The legs of the transformer are numbered on the base plastic. You must have pins 1-4 on the left side of the board when the transformer is installed.
REN32-TRANSFORMER.jpg REN32-STEP23.jpg
  • 25 - Install ten RJ45 modular jacks J1-J10 (PN# 571-5556416-1). Due to minor variations in manufacturing, some RJ45 jacks are a tighter fit than others. Care should be taken to ensure that the pins are aligned first before applying too much pressure to seat the locking lugs through the board.
REN32-STEP24.jpg
If you are unsure about your ability to build this board, then you should go to The Beginner's Setup Guide at this point. The Beginner's Setup Guide will walk you thru some initial tests to make sure that everything is working correctly before inserting the IC chips.
INSTALLATION NOTE:
Pin 1 of each IC must be aligned with pin 1 of the corresponding socket. This can be verified by noting that the notch on the IC is aligned with the notch on the socket.
  • 26 - Install the H11AA1 optocoupler U2 (PN# 782-H11AA1). Install with the notch up towards the top of the board.
REN32-STEP25.jpg
  • 27 - Install four PIC microcontrollers U6, U7 & U8 (PN# 579-PIC16F688-I/P). The PICs need to be programmed with the appropriate firmware before installation. More info on programming PICs can be found here. Install with the notch facing towards the right.
REN32-STEP26.jpg
  • 28 - Install two RS232/RS485 Interface ICs U4 & U5 (PN# 511-ST485BN). Install with the notch facing towards the right.
REN32-STEP27.jpg
  • 29 - Install the heat sink (PN# 532-577102B00) on voltage regulator U1. The mounting hardware and heat transfer compound are not included in the BOM since any common hardware can be used to attach the heat sink. If you don't have any heat transfer compound handy, you can use something like PN# 532-249. In the picture the heat sink is attached using a #4-40 x 3/8" machine screw and nut found at home depot.
REN32-STEP28.jpg
  • 30 - Install one fuse (PN# 504-GMA-10) and one fuse cover (PN# 534-3527C).
REN32-STEP29.jpg
  • 31 - Install the proper jumpers on JP1, JP2 and JP3 based on your use.
JP1 & JP2 Configuraton
The configuration of JP1 and JP2 depends on the type of communication being used:


RS-232 Communication (direct connect to PC)
  • JP1 installed
  • JP2 not installed
Reminder: This only applies to the first Renard SS board connected to the PC. The output of a Renard SS board to the next board is RS-485.


RS-485 Communication (output of a Renard board or output from a RS-485 adapter/converter)
  • JP1 not installed
  • JP2 installed (try removing if data communication issues are encountered)


JP3 Configuraton
  • Installed when running the Diagnostics Firmware
  • Normally not installed when running the Operational Firmware. But can be left installed if you don’t mind seeing the on-board LEDs responding with the associated channels.


Completed REN 32


REN32-FRONT.jpg
Congratulations! You have finished building your REN 32!

Mounting the REN 32 in an Enclosure

The REN 32 has mounting holes that line up with the standoffs in the common enclosures like the CG-500, CG-1000 and the CG-1500.

REN32-ENCLOSURE.jpg

Parts Listing (BOM)

IMPORTANT BOM INFORMATION:
Mouser part numbers are listed (unless otherwise noted) as a means of simplifying the listing. Mouser is not the only place to get these parts, they are used as the reference since they tend to have all the parts needed to complete the project. However, the parts can be procured from any electronics parts source that you prefer.
In the event that any of the following parts are not in stock at Mouser when you decide to order them, you can check the Part Substitutions wiki page and see if there any suggestions for alternative parts.


PART NUMBER
(Mouser PN# unless noted)
QTY REF NOMENCLATURE
511-LF50CV 1 U1 5 VDC Voltage Regulator
532-577102B00 1   Heatsink for Voltage Regulator
782-H11AA1 1 U2 Optocoupler, Bi-Directional Input
815-ACH-18.432-EK 1 U3 Crystal Clock Oscillator, 18.432 MHz
511-ST485BN 2 U4, U5 Differential Bus Transceivers
571-1-390261-2 2   IC Socket, 8 pin (for U4 & U5)
579-PIC16F688-I/P 4 U6-U9 PIC Microcontroller
571-1-390261-3 4   IC Socket, 14 pin (for U6-U9)
571-1-390261-1 1   IC Socket, 6 pin (for U2)
291-750-RC 2 R1, R2 Resistor, Carbon Film 750 ohms 1/4W 5%
291-120-RC 1 R3 Resistor, Carbon Film 120 ohms 1/4W 5%
299-1K-RC 2 R4, R7 Resistor, Carbon Film 1K ohms 1/8W 5%
299-27K-RC 3 R5, R8, R9 Resistor, Carbon Film 27K ohms 1/8W 5%
299-680-RC 1 R6 Resistor, Carbon Film 680 ohms 1/8W 5%
264-330-RC 1 RN1 Resistor Network, 6 pin, 330ohms 2%
625-1N5817-E3 4 D1-D4 Diode
78-1N5239B 1 D6 Diode, Zener 9.1V .5W
78-1N5229B 1 D5 Diode, Zener 4.3V .5W
604-WP710A10IT 2 FE, OE LED, 3mm Red
604-WP710A10GT 4 PWR, HB, ZC, SD LED, 3mm Green
140-REA222M1CBK1320P 1 C1 Radial Electrolytic Capacitor 16V 2200uF 20%
140-REA470M1CBK0511P 1 C2 Radial Electrolytic Capacitor 16V 47uF 20%
80-C322C104K5R 4 C3-C6 Capacitor, Radial Ceramic 50V 0.1uF
571-7969492 1 Power Terminals Terminal Block, 2 Pos 5.08 mm
571-5556416-1 10 J1-J10 Jack, Modular RJ45 PCB Mount Top Entry
538-22-03-2021 3 JP1-JP3 Header, 2 Pin
737-MSA-G 3   Shunt
504-GMA-10 1 F1, F2 Fuse, Fast Acting 10A
534-3517 2   Holder, Fuse Clip PCB mount 5mm
534-3527C 1   Cover, Fuse
838-3FD-412 1 TF1 Power Transformers 12.6VAC CT 6.0VA Dual Primary


If you are planning on ordering from Mouser Electronics you can use this Shared Project to make it easier to order the parts.

Hardcopy Instructions

Related Links

REN 32 Controller Board
Beginners Setup Guide For The REN 32
Troubleshooting Guide For The REN 32
Board Availability Information]
Renard Main Page
Renard Firmware
Part Substitutions
VIXEN
Glossary of DIYC Terms
Electronic Symbols