Instructions for installing components on the O2 sensor PCB board
1. Install the resistors
R2, R3, R4 – 1K ohm 0.25W (brown, black, red)
R5 – 390 ohm 0.25W (orange, white, brown)
R6 – 10K ohm 0.25W (brown, black, orange)
R7 – 270 ohm 0.25W (red, violet, brown)
R8 – 470 ohm 0.25W (yellow, violet, brown)
2. Install the rectifier diodes (the larger BLACK diodes) – note the orientation of the band at one end of the diode
D2, D3, D4 – 1N4001 - 50V 3A
3. Install the zener diode (smaller brown diode) – note the orientation of the band at one end of the zener diode.
D1 – 9.1V 0.5W
4. Install the capacitors.
C1, C2 – 0.1uF 50V.
5. Install the LED’s: Red led in LED1, Yellow led in Led5 and Green Led in Led6 on the board.
NOTE: The led has a flat side and one of the legs is shorter than the longer leg.
6. Install a jumper wire as noted in the PCB layout in page 3.
7. Install the IC chip LM324, note that the circle on the chip (which is pin 1) is matched up with the notch on the IC socket.
8. Strip out 5-10mm of the three wires (red, black and green), twist the wire ends.
+ve – red wire
-ve – black wire
O2 – green wire
9 Place the three wires thru a small hole in the side of the box and solder the wires to the correct place on the board.
10. Check for soldering on the board.
11. Test the board with the tutor’s instructions.
12. If the board is okay, insert the three wires thru a small hole of the box.
13. Strip 5mm of the three wire’s cover, twist the wire end.
14. Insert the crocodile clips to the other end of the three wires: 1x red clip to red wire, 2x black clips to black and green wire separately. Solder the wire end to the crocodile clips if necessary.
15. Apply the hot glue between the board and the box top. Wait for the glue to set for approx 1-2 minutes before placing inside the box.
16. Carefully insert the complete board inside the box.
17. Apply the wire tiers to both side of the box wall where the three cables go thru the hole of the box.
18. Carefully place the box cover to the box.
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