Welcome to the Sumo11 Expansion Board Step-by-Step Assembly guide
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Stage Two - Sockets & IC's
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Now you are ready to install the sockets and IC chips. Remember to keep all excess leads trimmed short so they don't touch anything on the main board when you put them together.

Components needed:
1 - 2x5 Pin Female Header ................................................(Bottom)
1 - 2x20 Pin Female Header ..............................................(Bottom)
2 - 47k Ohm Bussed Resistor Packs (10R-1-473) ...........(SIP1 & SIP2)
1 - 20K Ohm Thumbwheel .................................................(VR1)
1 - Mini Right Angle Pushbutton switch ...........................(SW1)
1 - Piezo Buzzer ..................................................................(Piezo)
4 - 3 Pin Male Header ..................................................(Servo's 0 thru 3)
2 - 20 Pin Sockets .........................................................(74HC244 & 74HC374)
2 - 16 Pin Sockets .........................................................(74HC138 & 74HC237)
1 - 14 Pin Socket ...........................................................(74HC132)
1 - 28 Pin Socket ...........................................................(NVRAM)
1 - 74HC244 IC
1 - 74HC374 IC
1 - 74HC138 IC
1 - 74HC237 IC
1 - 74HC132 IC
1 - NVRAM IC (BQ4011MA-100)

a) First you'll need to install the 2x5 pin header and the 2x20 pin header. These are inserted from the bottom side of the board and soldered on the top side, unlike all the rest of the components. The bottom side of the board is the side that does NOT have the white silk-screened letters written on it.
The image below shows how these headers should go.

b) Next, the two SIP resistor packs go at SIP1 & SIP2. Pin 1 of both should point towards the outsides of the board. Pin one of these resistors is the side that has the mark on it.

c) Install the Thumbwheel at VR1.

d) Place the Mini right angle Push-button start switch at SW1.

e) Install the mini Piezo buzzer where it says Piezo. Be sure to install it the right way, both the buzzer and the board are marked for positive.

f) In your kit you'll find four 3 pin male headers needed for the servo outputs. Install them at Servo 0 thru 3.

g) Now for all the sockets. These can really only fit in their appropriate places, just be sure to align the notches with the ones in the drawings on the board.

h) Insert the IC chips into the sockets. Each chip has it's label printed on it. Match them up to the label printed on the board and insert them. The pins are usually spread wider than the socket and generally require an insertion tool, but what I have done in the past is lay the chip on it's side and gently press down until the pins are squeezed inward and then flip it and do the same to the other side. Remember to line up the notches when inserting them!

i) The final step is to install the big memory chip. Being careful not to touch the pins, line up the notches and evenly press it into its socket. You will NOT need to squeeze these pins closer together like the other IC's.

Your board should now look like the picture below.

Click on the image to enlarge

Before you can mount the Expansion board onto the main board you'll need to set the mode jumper from single to expanded and remove the 4 jumpers from the 40 pin header as shown.

Click on the image to enlarge

You can now mount your expansion board onto the main board.
The expansion board came with an LCD display, you will need to solder the 14 pin male extension header to the LCD screen, then plug it into the LCD port and you're ready to go!

Below is a picture of what the final Sumo11 board should look like.

For those with a Revision 1.0 expansion board, you will need to add a ground wire and a pull-up resistor wire as shown below. (All expansion boards to date 12/09/03 are Rev 1.0)



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Revision 1.0 expansion board, list of issues:
1) Pin 22 of the memory did not get routed to ground.
2) The first Digital Input did not get routed to a pull-up resistor.
3) The last two Digital Inputs are swapped.
4) The silk screen print is too small to read.
5) The Start and Stop logic is swapped.
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Your Sumo11 controller is now complete, you can move on to Stage three for instruction on installing Interactive C and running the test program.