Solar PCB v0.6

Here is the Solar PCB v0.6:

Here is the schematic:

Start with the blank PCB, shown here top on left with AMSAT logo, bottom on the left:

The diodes D1 - D6 and resistors R3 and R4 are installed vertically:

The polarity of this diode is marked by a white band, which is on the left side in this photo, which matches the schematic symbol on the PCB for D1:

Here is the polarity of the diodes:

They are installed on the PCB top then soldered on the PCB bottom. Solder one lead on each diode then flip the board over and double check polarity, insertion, and straightness before flipping board back over and soldering the other lead:

Trim the leads after soldering:

Do the same for the resistors, but resistors do not have a polarity to worry about.

On the bottom, install the two 1x6 female headers for the INA219 boards, and the 2x20 GPIO female header. Note you can skip the 1x6 female headers if you want to directly solder the INA219 boards to the PCB:

Use blue putty to hold the 1x6 female headers in place, straight and vertical:

Flip the PCB to the top and solder. Solder one pin on each header, then flip board over and double check insertion and straightness.

Here's how it looks with all the components installed on the bottom of the PCB:

Next, flip the board and install the JST connectors on the top of the PCB. Some connectors click in place. If yours don't, you should add a drop of superglue gel or other adhesive to secure it to the PCB so it won't pop out when you are unplugging solar panels:

Note that these connectors have a polarity. Make sure the slot in the connector faces to the outside of the PCB:

Here's how the board looks with them all installed:

Flip the board over and solder one pin on each one then flip back and check insertion, orientation, and straightness.

Next install the four 1x6 female headers and the 1x6 male header used for testing the INA219 boards

Use blue putty to hold them in place and, as always, only solder one pin on each board before checking for straightness and insertion:

Here's how they look installed:

Next, install the Qwiic connector.

This is optional, but very useful if you ever want to add additional I2C sensors for the Raspberry Pi Zero. First you will install the 1x4 male pin header with the long pins through the PCB. Solder them on the bottom:

Then insert the red Qwiic board, checking that you have it in the right way by checking the pin labels. Make sure it is horizontal and straight before soldering on top:

Here's how the top of the PCB looks:

Before soldering your INA219 boards, I recommend testing them first. You can do this by plugging your Pi Zero with the SD card which has had the software installed. You will need to power the Pi Zero by connecting a power cable to one of the micro USB connectors. When the Pi boots up, login to the Pi and type the command:

CubeSatSim/telem

You will see this output:

Now, take one of your INA219 boards and plug it in as shown here:

While holding it slightly tilted so the pins make contact, type the command again CubeSatSim/telem and now you should see this output:

Repeat for all of your INA219s including the one for the Battery board. If they all test OK, continue soldering them.

Power down and unplug the Pi Zero and flip the PCB to the bottom. Solder the two INA219 boards to their pin headers for the bottom:

First, insert the 1x6 male pin headers into the female sockets, long side of the pins into the socket. If you aren't using the female sockets, just insert the pins into the PCB.

Place the INA219 board on top and support using blue putty so it is level and straight.

Then solder the pins:

After they are installed, you need to set the address jumpers A0 and A1 on the INA219 boards. Only the right one needs to be set in this case. Add a small blob of solder on the A0 jumper as shown here:

Here they are installed with addresses set:

Now flip the PCB to the top and do the same for the four INA219s on the top:

First insert the 1x6 pin headers into the female sockets:

Then plug in the boards and support so they are horizontal and straight:

Then solder the pins on top:

The addresses need to be set.

Here's the complete board:

The next step is Step 8. Board Stack