DIY Speaker Kit - Manual

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1 DIY Speaker Kit - Manual

2 Technology Will Save Us WELCOME TO THE DIY SPEAKER MANUAL This DIY kit comes with a custom designed amplifier called the Uber Amp 9000 and all of the components you need to make your own set of speakers out of any material. This is a great way to learn how to solder, understand how sound works and make something useful for your listening experience.

3 Technology Will Save Us GETTING STARTED Stay Safe Keep safe when making this kit! Wear protective eye wear when soldering and clipping component legs. Top Tips Keep an eye out for the top tips. They are highlighted in an orange box like this! Making Time The kit takes about 2 fun filled hours to complete - depending on how creative you get with the construction of your speakers. Further Resources Information on the best materials and shapes for your DIY Speaker can be found in the resource section! Learn how different materials and speaker shapes can effect the sound. Choose one that s best for you! Useful Appendix Further information on all the components in this kit can be found in the Appendix at the back of the manual. Learn about their use within the circuit you are building. ENJOY! 4

4 SOLDERING 101 STEP 1. Place the component into the PCB (Printed Circuit Board), make sure it goes in the correct way and it is sitting right against the board. Bend the legs to keep the component in position. STEP 2. Turn the PCB around. Place the soldering iron tip at the point on the PCB where the leg of the component meets the solder pad. Heat for about 3-4 seconds. 5 Soldering

5 Technology Will Save Us STEP 3. Using your other hand, add solder to the heated pad. Add enough solder to cover the pad and the base of the components leg. Remove the solder and leave the iron for another second. STEP 4. After soldering both legs, take your side cutters and remove the excess component leg. If you make a mistake, re-heat the join and use a solder sucker to remove the molten solder. Soldering 6

6 Technology Will Save Us Components: 1. 1 X 10 K Ohm Resistor ( Brown, Black, Orange, Gold ) 2. 2 X 4.7 Ohm Resistors ( Yellow, Violet, & Gold ) 3. 1 X 33 Ohm Resistor ( Orange, Orange, Black, Gold ) 4. 1 X Diode (black tube with grey mark on one end) 5. 1 X Red LED (Light Emitting Diode) 6. 1 X Stereo Input Jack 7. 1 X Switch 8. 1 X 8 Pin black socket 9. 2 X 100 nf (nano Farad) Capacitors X 10 nf Capacitors X 10 uf Capacitors (cylinder) X Speaker wire connectors (Terminal Block) X 4.7 K Ohm Potentiometers (variable resistors) X 8 Pin Integrated Circuit (IC) TDA2822 amplifier X Battery Holder X PCB - printed circuit board X Audio cable X Double Sided Foam Tape X Exciters (Speakers) 20. 1X Exciter cable Not Included in Kit: 21. Blue or White Tack (not included, but helpful for soldering) 22. Solder 23. Solder Sucker 24. Wire Cutters 7 Components

7 Technology Will Save Us Top Tip Some components may look slightly different to the ones above, don t be alarmed, this is normal! Components 8

8 1 Diode Bend the diodes legs 90 degrees. Make the bend close to the black cylinder, around 3mm away from either side. Carefully insert it into the correct place on the PCB (D1). Top Tip The diode has a direction this means it must go into the PCB the right way! Make sure you match the grey mark on the diode with the similar mark illustrated on the PCB. 9 Step 1

9 Technology Will Save Us Make sure the diodes legs are pushed all the way through the PCB and the diode is flat on the surface. Turn the PCB around and bend the legs of the diode 45 degrees. This prevents the diode from moving. Top Tip Fix the PCB to the table with blue tac. It will keep it steady when you begin soldering. Step 1 10

10 Technology Will Save Us Soldering Now you have to solder the diode into place. Follow the simple soldering steps at the front of the manual - this will leave you with a perfectly soldered joint! Top Tip Solder is basically melted metal - so it is very hot! The hot metal will connect to surfaces that are similarly heated - so make sure that the pad, the component leg and the solder are equally heated. If not, you ll end up with a cold joint, which will result in an F in your soldering exam! 11 Step 1

11 Technology Will Save Us After soldering both the legs, take your side cutters in one hand. Hold one of the legs of the diode, and clip at the legs base. Repeat for the other leg. Top Tip You are holding the leg to prevent it from flying into your or someone elses eyeball! Please remember that eyeballs are not easily replaceable and you should always be very careful when clipping the legs off of your components. Step 1 12

12 2 Resistors Find all your resistors. Take one of the resistors and bend both of the legs as close to the body as you can. This ensures that it will sit snugly against the PCB. Repeat this with all the resistors. Top Tip You can find out more about the resistors in the appendix at the back of the manual! 13 Step 2

13 Technology Will Save Us Place the following resistors in this order, onto the PCB. R1: 10K Brown, Black, Orange, Gold) R2: 33Ohm (Orange, Orange, Black, Gold) R3&R4: 4.7Ohm (Yellow, Violet, Gold, Gold) Soldering Bend all your resistor legs so they don t fall out when you turn over the PCB. Solder them into place. Once soldered, clip the legs. The good news: You ve just finished the resistors! Top Tip You may want to clip the legs as you go, it will allow more room for soldering the others. Step 2 14

14 3 Capacitors We ll begin by soldering the non-polarized capacitors. These can go into the PCB any way around. Find the 10nF, and 100nF blue capacitors. Top Tip These guys look the same so look out for the number 10 written on the side! Insert the capacitors in the following positions. C4: 10nF capacitor C5 & C6: 100nF capacitors Once soldered into place, clip the legs! 15 Step 3

15 4 Electrolytic Capacitors Warning! These ones are polarized, they have to go into the PCB in a particular way. Take the 10uF capacitor and look at its legs. You ll see that one is longer than the other. If you look at the PCB, you ll see a + next to one of the plated holes. The long leg is the plus sized, so it should be inserted next to the +. Top Tip Learn more about these components in the appendix at the back of the manual. Step 4 16

16 Technology Will Save Us With this in mind, insert the electrolytic capacitors into the following places. 10uF capacitors: C1, C2 & C3 Turn over the PCB and bend the legs of all the electrolytic capacitors. Solder them all in and clip the legs. You are now done with the capacitors. 17 Step 4

17 5 LED (light emitting diode) Take the LED and look at it s legs. You ll see that one is longer than the other. This means that it has to be inserted into the PCB in the right way! The longer leg is called the Anode - which likes to have power. The shorter one is called the Cathode - which likes to have ground. Insert the LED into the correct location on the PCB - look for the LED illustration! Solder it into place. Step 5 18

18 6 8 Pin Black Socket Take the 8 Pin black socket and insert it where the PCB is marked TDA2822. Solder the socket into place. Top Tip There is a notch in the 8 Pin socket, make sure this lines up with the notch illustrated on the PCB. 19 Step 6

19 7 Stereo Jack Take the black stereo jack and place it onto the PCB. It will slot very comfortably in place where the PCB says HEADPHONE JACK. Solder it and move onto the next component. Switch Insert the switch into the position marked S1 adjacent to the LED. Solder all 5 of the pins into place. Step 7 20

20 8 Potentiometer Find the potentiometer, this goes next to the switch. Place it onto the PCB and solder into place. Top Tip The potentiometers legs are already short. You won t need to clip these! 21 Step 8

21 9 Integrated Circuit (IC) The IC is an amplifier chip. It must be placed inside the 8 pin Socket you soldered previously. If you look carefully at the chip, you ll see a notch in the centre of the one end. Top Tip A socket is used to make sure that we don t over heat the IC by soldering it directly. Carefully insert the IC into its socket so that the notch is directed towards the LED. Step 9 22

22 Technology Will Save Us The integrated circuit should sit snugly into the socket. At this stage, your PCB should look like this! Terminal Block Take your black terminal block connectors and solder them into place! They go on the far left of the PCB. 23 Step 9

23 10 Exciter The exciter (speaker) must be attached to the pair of speaker wires. Take both of your wires and twist the ends of each. This will give them a nice neat finish that is easy to attach to the terminal and exciter. Trim the ends to around 10mm. Step 10 24

24 Technology Will Save Us Next feed one of the wires through the small hole on the exciter. Solder the wire into place to create a good connection with the mettal pad beneath. Repeat with the other wire. Top Tip Keep the exciter steady while soldering with a blob of blue tac. 25 Step 10

25 Technology Will Save Us Your speaker connector (Terminal Block) has 2 ports. You must attach your 2 exciter wires to this connector. One in each port. To do this, depress one of the levers on the terminal block and then insert one of the wires. Repeat for the other port and other wire. Once both wires are inserted, the amp is ready to be tested. Step 10 26

26 11 Battery holder Before we solder the battery holder in place, it is a good idea to test test test! Insert 2x AA batters into the battery holder. 27 Step 11

27 Technology Will Save Us Insert the battery holder into the PCB from behind. It goes in on the edge of the board closet to the IC. Bend the legs out to keep it in place. It will also ensure that they make contact with the conductive pads which we will solder them to later. Turn the switch on. Does the LED turn on? If so, congratulations! If not, try the following. - Press down on the battery legs to ensure contact. - Try the switch again in both directions, while holding the battery legs in place. Top Tip Check the forum at twsu.co/forum for more support. - Are you sure the batteries are in? - Go back through the manual and make sure everything is in the correct place. Step 11 28

28 Technology Will Save Us Remove the battery holder and find the double sided foam tape. Attach the foam tape to the back of the battery holder on the other end to the legs. Then reveal the other sticky side of the tape before inserting the legs back into the PCB. Solder the legs into place and carefully trim any excess. 29 Step 11

29 12 Stereo cable Now its time to check everything is working. Plug in your audio cable and attach to a music playing device. You should feel the vibrations. Use the potentiometer to adjust the volume and see the vibrations increase and decrease. Step 12 30

30 Congratulations! Using the box: You have now completed your amp, and attached it to your exciter! All that is left is to attach the exciter to various materials and begin experimenting with sound waves and surfaces. Enjoy exploring different material s responses to the vibrations emitted by your exciter. Design your speaker: Then decide on what material you want to become your speakers. Use the sticky pad on your exciter to permanently fix it to your chosen material! 31 Congratulations

31 Technology Will Save Us Materials: Corrugated card Paper Polystyrene Wood Shapes: Cone Cube Sphere Cylinder Pyramid Materials 32

32 Making your Speaker: Play and experiment with different shapes and materials to make yourself a unique DIY Speaker. Here are some examples of the DIY Speaker Kit in action! 33 Making your speaker

33 Technology Will Save Us Making your speaker 34

34 Component Appendix Resistors - Resistors are used in a circuit to restrict the flow of electrical current and stop things from blowing up! The resistors in measured in Ohms. Capacitors - A capacitor is like a big bucket, it stores up charge, waits until its full and then releases it all in one go. How much charge depends on the size of the capacitor, measured in farads. LED - A light-emitting diode is your basic electronic light. Its also a Diode - which means it only allows current to flow in one direction. That is why the legs are different lengths. Stereo Input Jack - This is the connection between your audio device and circuit. 35 Components

35 Technology Will Save Us 8 Pin intergrated Circuit - An Integrated Circuit also know as an IC is a whole circuit in itself, but very very small and made of silicon. The chip in this circuit is a TDA2822 amplifier chip - used in old laptops and portable music devices. 8 Pin socket (Dil Socket) - An 8 Pin socket holds the integrated circuit to the PCB. It protects the IC from being damaged during soldering. Diode - A Diode is a component that allows current to flow in just one direction. It must go into your circuit the correct way round, the white band indicates the negative side of the diode. Terminal Block - The Terminal Block creates a connection between the exciter cable and circuit board. It creates this connection with a pair of sprung clamps so cables can easily be changed, no soldering neccessary! Components 36

36 Component Appendix Potentiometer - A potentiometer is a resistor that you can control! Turning the knob on the potentiometer increases and decreases the amount of resistance a bit like a tap and the flow of water. Switch - A basic switch. It allows current to flow in one direction when it is switched on by completeing the circuit. When switched off it breaks the circuit stopping the flow of current. Battery Holder - Securely holds two AA batteries in place. Exciter Cable - Transfers the now amplified audio signal from your audio device to the exciter to be transferred to audible sound. 37 Components

37 Technology Will Save Us Audio Cable - The audio cable bridges your music or sound player and your amplifier circuit - carrying the electrical signals from the output of the music player to the input of the amplifier. Exciter - The exciter vibrates according to the sound its playing. It transfers this vibration into the material it is touching (or it excites the material) Sound is just a whole lot of vibrations. So the lighter and more rigid the material, the better the transfer of vibration - and the louder the sound you hear! Components 38

38 Technology Will Save Us Thank You! Technology Will Save Us exists to educate and inspire people to make, tinker and experiment creatively with technology as a way of unleashing new possibilities. Devices, gadgets, computers are all a part of out everyday life and yet most people know so little about what these things are made of, let alone how to fix them or create new uses for them. We believe that the opportunity for technology to play a richer, more creative role in our lives has yet to be explored. 39

39 Contact Interested in more classes? Have an idea for a workshop we should teach? Do you want to teach a class? We d love to hear from you. Contact us by or find out more on our website - 40

40

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