• Assembly
• Electrical Fabrication Sources
• Factory Testing

Assembly Files

The assembly files are generated from the schematics and board layout source files which were created in CADsoft EAGLE.

The files are all stored in a Git repository at GitHub.

• Board Layout DXF
• Gerber files
  • .top Top Copper Layer
  • .smt Top Soldermask
  • .slk Top Silkscreen
  • .tsp Top Solderpaste
  • .bot Bottom Copper Layer
  • .smb Bottom Soldermask
  • .bsk Bottom Silkscreen
  • .bsp Bottom Solderpaste
  • .oln PCB Outline
  • .drd Excellon Drill Data
  • .drl Basic Drill tool information
  • .dri Extended Drill tool information

Special Assembly Instructions

• See NOTES: on ASSY drawings for general notes
• Ensure no excess solder is wicked into J0 (USB Micro Connector). Verify a USB Micro cable can successfully connect
• Ensure J0 (USB Micro Connector) is completely flush to the PCB before/after reflow. Ensure pins at rear of connector are not lifted off pads.
• Apply epoxy to J0 for additional structural rigidity
• Ensure J2 (OBD-II connector) pins are flush with PCB before soldering
• Ensure J2 (OBD-II connector) is horizontal to PCB before soldering
• LED1 and LED4 (through hole RGB LEDs) must be bent 90 degrees towards front edge of PCB
• Ensure both through hole electrolytic capacitors (C2 and C3) are flush against PCB before soldering.
• Ensure part Q2 (12MHz crystal) is oriented such that the long dimension follows the centerline on the silkscreen layer.

Assembly file output instructions

If you modify the schematics and need to regenerate the assembly files, follow these instructions.

• Verify silkscreen and PCB Frame artwork reflects accurate revision
• Update layers 125 and 126 - text on top of each component should identify the part designator
• Delete all content on layer (144) DrillLegend
• run “drillegend.ulp”: Use all default values, click OK.
• Reselect layer (144) and move the newly created drill legend back onto the frame
• Verify SSC-EAGLE-2Lyr_v1.0.0.3.dru is loaded as current design rules file
• Turn on all copper and stopmask layers, turn off silkscreen layers (skip silkscreen error checking, silkscreen will be clipped by assembly house)
• Preform DRC/ERC check
• run “drillcfg.ulp”: select “Inch” as output format. Click OK. Save.
• run “excellon.cam” in the CAM processor, click “Process Job”
• run “2LPlus-Sunstone.cam” in the CAM processor, click “Process Job”
• Double check all gerber files using a gerber file viewer (like gerbv).
• Deselect all layers, select only the following layers: (17)Pads, (18)Vias, (20)Dimension, (21)tPlace, (22)bPlace, (23)tOrigins, (24)bOrigins, (49)Reference, (51)tDocu, (52)bDocu, (125)tAssy, (126)bAssy
• run “dxf.ulp”: deselect “Fill Areas”, make sure “mm” is selected under the “units” header. Save the DXF file.
• Deselect all layers, select only the following layers: (17)Pads, (18)Vias, (20)Dimension, (21)tPlace, (23)tOrigins, (48)Document, (49)Reference, (51)tDocu, (125)tAssy, (144)DrillLegend
• Hit print (Ctrl+P), select “Print to File (PDF)” as the printer, select vehicle-interface_ASSY_TOP.pdf, paper size A4, scale factor 1. Click OK.
• Deselect all layers, select only the following layers: (17)Pads, (18)Vias, (20)Dimension, (22)bPlace, (24)bOrigins, (48)Document, (49)Reference, (52)bDocu, (126)bAssy, (144)DrillLegend
• Hit print (Ctrl+P), select “Print to File (PDF)” as the printer, select vehicle-interface_ASSY_BOT.pdf, paper size A4, scale factor 1. Click OK.
• Deselect all layers, select only the following layers: (1)Top, (16)Bottom, (17)Pads, (18)Vias, (20)Dimension, (21)tPlace, (22)bPlace, (25)tNames, (51)tDocu, (52)bDocu
• Zoom in so that PCB is centered in the screen and fills the window as much as possible.
• Select File->Export->Image. Select vehicle-interface.brd.png. Set “Resolution” to 600. Set “Area” to “Window”.
• In the schematic window, hit print (Ctrl+P), select “Print to File (PDF)” as the printer, select vehicle-interface.sch.pdf, paper size A4, scale factor 1, page limit 1 Click OK.
• In the schematic window, select File->Export->Partlist. Select “vehicle-interface.parts.txt”. Click OK.
• Manually compare “vehicle-interface.parts.txt” to “vehicle-interface.bom.xls”. Make sure the two lists are consistent.
• Open “CHANGELOG.xls”. Update the file to reflect the new revision.
• Create a zip archive with the following files (at least):
  • vehicle-interface.pdf
  • vehicle-interface.brd.png
  • vehicle-interface_ASSY_TOP.pdf
  • vehicle-interface_ASSY_BOT.pdf
  • vehicle-interface.tsp
  • vehicle-interface.top
  • vehicle-interface.smt
  • vehicle-interface.smb
  • vehicle-interface.slk
  • vehicle-interface.oln
  • vehicle-interface.gpi
  • vehicle-interface.dxf
  • vehicle-interface.drl
  • vehicle-interface.dri
  • vehicle-interface.drd
  • vehicle-interface.bsp
  • vehicle-interface.bsk
  • vehicle-interface.bot
  • vehicle-interface.bom.xls
  • vehicle-interface.sch
  • vehicle-interface.brd
  • CHANGELOG.xls