Assembly procedure for USB Power Output 2HP

Here is the recommended order for assembling USB Power Output 2HP module. Please read through the entire procedure before beginning to solder. Feel free to adapt the procedure to your preference.

This is the front side of the board we are populating.

This is the back side of the board we are populating.

SMD components

Components mounted on the back side

Install K5, the 2-way screw terminal connector. Orient the connector so that the wires can exit towards the side of the module where there is the most free space in your case/rack.

Components mounted on the front side

I highly recommend not soldering the components that are attached to or aligned with the front panel immediately.

Instead, follow these steps: First, position the jack sockets and potentiometers on the PCB without soldering them. Second, place the front panel over the components and secure it by tightening the nuts of a couple of jack sockets (preferably the two furthest apart) and the potentiometers. If possible, tighten all the nuts.

With everything held in place, solder a single pin on each component. Check the alignement and reflow the soldered pad of any component that needs adjustment.

When you're satisfied with the alignment, finish by soldering the remaining pads.

This process ensures perfect alignment of the controls and prevents mechanical stress on the solder joints and PCB. If you solder the pins before tightening the nuts and screws, you risk damaging the PCB pads, bending the front panel, and misaligning the components. The main challenge is holding everything in place prior to soldering. If necessary, you can tack-solder one pin per component before positioning the front panel. Just remember to reflow that solder joint after tightening all nuts to release any tension on the pad.

Bolt the 3x 15mm hex standoffs on the PCB, using the 3x M3 screws and the 3x M3 spring washers.

Snap the four vertical USB-A connectors into place.

Install LED D1. Be careful: LEDs are polarized. The longer leg is the anode and must be placed in the round pad. The shorter leg is the cathode and is to be inserted in the square-shaped pad, also marked on the PCB with a thicker band. Reminder: If you are using a LED spacer, add it before soldering.

Place the front panel: secure it with the three black M3 hex screws and the three black plastic washers.

Finally, solder all the components. Note that the screw terminal block plastic body is in contact with the ground pads and tabs of the adjacent USB connectors: the plastic might melt a little during the soldering process. This is expected and should be fine.

And here is the finished board