1. RockOn! 2009 1 RockOn! Structure Build RockOn! 2009

2. 2 Structures Overview: -Do not break configuration of you tested and armed payload -In other words, do not disconnect anything -Do not install the jumper or short RBF wires during this operation -You will not be able to erase and rearm you payload

3. RockOn! 2009 3 Structures Overview: -Open your structures kit and verify its contents. -ESD protection should be utilized during the entire building process! -Make sure anyone handling the hardware is protected from ESD damage. -If any issues arise raise your hand for assistance.

4. RockOn! 2009 4 Structural Kit Overview: Nuts and Bolts Purple M3.0x10 (2) M2.0 nuts (2) Light Green M2.5x10 (3) M2.5 nuts( 3) Black M3.0x25 (4) Red M3.0x35 (4) Light Blue M3.0x10 (4) Red M2.0x10 (2) M3.0 nuts (16) Light Green M3.0x10 (2) *Bolts and nut are 1:1 scale Nylon spacers (24)

5. RockOn! 2009 5 Structural Kit Overview: Brackets Z Accelerometer bracket (1) ‘L’ Battery bracket (1) Battery bracket (1) G-Switch bracket (1)

6. RockOn! 2009 6 Structural Kit Overview: Adding Electrical Tape Z Accelerometer bracket Leaving the holes free, add electrical tape to the Z accelerometer on the three-hole piece.

7. RockOn! 2009 7 Structural Kit Overview: Parts from other kits G-switch (1) Green LED (1) Blue RBF Wire (several feet) Red LED with connector (1)

8. RockOn! 2009 8 Structural Kit Overview: Parts from other kits Z Accelerometer Board (1) Geiger Board (1) AVR Board (1)

9. RockOn! 2009 9 Structural Kit Overview: Tools Screwdriver Set Small Wrench Needle Nose Pliers

10. RockOn! 2009 10 Z Acc (green) Structural Kit: Mounting Plate AVR (black) Geiger Board (red) G-Switch (purple) Batteries (blue)

11. RockOn! 2009 11 Let’s Start Building! RockOn! 2009

12. 12 Structural Kit: Completed Plate

13. RockOn! 2009 13 Step 1: AVR Mounting -Find the M3.0x25 Black bolts for the AVR. -Mount the AVR in the orientation shown on the following slide using nylon spacers. -The nylon spacers will be above and below the board as shown. -AVR holes are colored black on the mounting plate. -Hand tighten with an M3.0 nut followed by a final ½ turn using the wrench and screwdriver.

14. RockOn! 2009 14 Step 1: AVR Mounting x4 for all holes on the AVR ***Note the orientation of the AVR***

15. RockOn! 2009 15 Z Acc Step 1: AVR Mounting [Before] AVR Geiger Board G-Switch Batteries

16. RockOn! 2009 16 Step 1: AVR Mounting [After]

17. RockOn! 2009 17 Step 1: AVR Mounting [After close-up] Bottom-Up View Side View Top Down View

18. RockOn! 2009 18 Step 2: Z Accelerometer Mounting -Find the M3.0x10 green bolts for the Z accelerometer bracket. -Mount the Z accelerometer bracket as shown. -Make sure the electrical tape is oriented on the correct side of the Z accelerometer bracket. -Z accelerometer holes are colored green on the mounting plate. -Hand tighten with an M3.0 nut followed by a final ½ turn using the wrench and screwdriver.

19. RockOn! 2009 19 Step 2: Z Accelerometer Mounting [Before]

20. RockOn! 2009 20 Step 2: Z Accelerometer Mounting

21. RockOn! 2009 21 Step 2: Z Accelerometer Mounting [after]

22. RockOn! 2009 22 Step 2: Z Accelerometer Mounting [after close-up] Top View Bottom View

23. RockOn! 2009 23 Step 3: Z Accelerometer Mounting -Find the M2.5x10 Light Green bolts for the Z accelerometer. -Mount the Z accelerometer as shown. -Hand tighten with an M2.5 nut followed by a final ½ turn using the pliers and screwdriver. -*** Use three nylon washers between the bracket and PCB of the accelerometer. *** -Hand tighten with an M3.0 nut followed by a final ½ turn using the wrench and screwdriver.

24. RockOn! 2009 24 Step 3: Z Accelerometer Mounting [before]

25. RockOn! 2009 25 Step 3: Z Accelerometer Mounting

26. RockOn! 2009 26 Step 3: Z Accelerometer Mounting [after]

27. RockOn! 2009 27 Step 3: Z Accelerometer Mounting [after close-up] Front View Behind View Top Down View (note the washers used for spacing) Caution! These are the leads in question.

28. RockOn! 2009 28 Step 4: Z Accelerometer Connection -Connect the four pin header to the ‘Z main’ location on the AVR as shown. -Make sure you connect Red to “+” and Black to “-”.

29. RockOn! 2009 29 Step 5: Geiger Counter Mounting -Using hot glue, stake down the red wire leading off the Geiger counter to the Geiger PCB near the bend in the wire.

30. RockOn! 2009 30 Step 5: Geiger Counter Mounting -Make sure the red Geiger wire is staked down before you mount the Geiger counter. -Using four nylon spacers and the Red M3.0x35 bolts mount the Geiger Board to the plate as shown. -Hand tighten with an M3.0 nut followed by a final ½ turn using the wrench and screwdriver.

31. RockOn! 2009 31 Step 5: Geiger Counter Mounting Side View Bottom View

32. RockOn! 2009 32 Step 6: Geiger Counter Connection -Connect the three pin header on the Geiger counter to the breadboard on the AVR as shown. Connect black to the black wire, red to the red wire as depicted.

33. RockOn! 2009 33 Step 6: G Switch Bracket Mounting -Find the G Switch bracket and mount to the plate as shown. -The mounting bolts are two M3.0x10 colored purple. -The holes to be mounted are closest the bend in the ‘L’ bracket. -Finger tighten with an M3.0 nut followed by a final ½ turn using the wrench and screwdriver.

34. RockOn! 2009 34 Step 6: G Switch Bracket Mounting [after]

35. RockOn! 2009 35 Step 6: G Switch Bracket Mounting [after close-up] Top View Bottom View

36. RockOn! 2009 36 Step 7: G Switch Mounting -Find the G Switch and mount to the G Switch bracket. -The mounting bolts are two M2.0x10 colored red. -Finger tighten the bolts with M2.0 nuts plus an additional ½ turn using the pliers and screwdriver.

37. RockOn! 2009 37 Step 7: G Switch Mounting

38. RockOn! 2009 38 Step 7: G Switch Mounting [After]

39. RockOn! 2009 39 Step 7: G Switch Mounting [After Close-up] Front View Back View

40. RockOn! 2009 40 Step 7: G Switch Mounting -Connect the G Switch header to the AVR board location labeled ‘G- switch’. -Since there is no polarity to this shorting mechanism, the orientation of the wires does not matter.

41. RockOn! 2009 41 Step 7: G Switch Mounting [After]

42. RockOn! 2009 42 Step 8: Battery Bracket Mounting -Acquire Flight Batteries in your structures kit. -Find both battery brackets and mount to the plate as shown. -Mount all brackets using m 3.0x10 bolts colored light blue. -Hand tighten with an M3.0 nut followed by a final ½ turn using the wrench. -Mount the ‘L’ bracket first pushing the batteries flush with it on the plate.

43. RockOn! 2009 43 Step 8: Battery Bracket Mounting [Before]

44. RockOn! 2009 44 Step 8: Battery Bracket Mounting

45. RockOn! 2009 45 Step 8: Battery Bracket Mounting [After] -Orient the battery connectors to lead the extending wires to the left. -Check battery voltage and record

46. RockOn! 2009 46 Step 8: Battery Bracket Mounting [After close-up] Top View *Note flushness of batteries with ‘L’ bracket Bottom View

47. RockOn! 2009 47 Step 8: Battery Connection -Connect the header from the batteries to the ‘Power’ location on the PCB. -The header should be right next to the ‘RDY’ and ‘ON’ locations within the PCB. -**Note the Red lead from the battery should connect to the ‘+’ indication on the PCB.

48. RockOn! 2009 48 Staking and Mounting RockOn! 2009

49. 49 Step 1: Mounting the AVR -Slide some nylon threading underneath the AVR socket and tie down to the socket as shown. -The nylon should be tightly secured to the chip. Have a partner (who is also ESD protected) help you tie a tight knot.

50. RockOn! 2009 50 Step 1: Mounting the AVR

51. RockOn! 2009 51 Step 2: Tying sensor wiring [plate overview]

52. RockOn! 2009 52 Step 2: Bundling Wires -Each set of wires on the board should be bundled two or three times. -Use the nylon threading to bundle the wires together as shown. -Use a square knot to tie the nylon threading and trim the excess leaving an inch remaining. -USE CAUTION!! Don’t snip your wiring while doing this!!!

53. RockOn! 2009 53 Step 2: Bundling Wires AVR Overview

54. RockOn! 2009 54 Step 2: Bundling Wires Plate Overview

55. RockOn! 2009 55 Step 3: Mounting Battery wires -Orient the battery wiring as shown and stake to the AVR bolt indicated. -Wrap nylon thread around the bolt as shown and tie around the bundle of battery wires. -The wires are now secure to the plate.

56. RockOn! 2009 56 Step 3: Mounting Battery wires

57. RockOn! 2009 57 Step 3: Mounting Battery wires

58. RockOn! 2009 58 Step 3: Mounting Battery wires [plate overview]

59. RockOn! 2009 59 Step 4: Mounting G-switch wires -Orient the G-switch wiring for mounting to the AVR bolt indicated. -Wrap nylon thread around the gold battery bracket as shown and tie around the bundle of G-switch wires. -Wrap nylon thread around the bolt as shown and tie around the bundle of G-switch wires. -The wires are now secure to the plate.

60. RockOn! 2009 60 Step 4: Mounting G-switch wires

61. RockOn! 2009 61 Step 4: Mounting G-switch wires

62. RockOn! 2009 62 Step 5: Mounting Geiger wires -Orient the Geiger wiring for mounting to the Geiger bolt indicated. -Wrap nylon thread around the Geiger bolt as shown and tie around the bundle of Geiger wires. -The wires are now secure to the plate.

63. RockOn! 2009 63 Step 5: Mounting Geiger wires [Geiger PCB overview]

64. RockOn! 2009 64 Step 5: Mounting Geiger wires [Geiger PCB overview]

65. RockOn! 2009 65 Step 5: Mounting Geiger wires [plate overview]

66. RockOn! 2009 66 Indicator LED and RBF Wiring RockOn! 2009

67. 67 Step 6: LED Mounting [General] -Make sure the Green LED is attached to the ‘ON’ header with the correct polarized orientation. -Additionally, make sure the connector for the Red LED is attached to the ‘RDY’ header in the correct orientation. -Extend all three sets of wires underneath the plate using the notch nearest the AVR as shown.

68. RockOn! 2009 68 Step 6: LED Mounting [General] -Use copious amounts of hot glue without being overly excessive. -Keep the tip of the hot glue gun from touching hardware, only molten glue should touch the hardware.

69. RockOn! 2009 69 Step 6: LED Mounting [General] -There are two orientations of LED mounting for the structures build. -If your plate serial number is odd (ending in 01, 03, 05) orient the LEDs in the first orientation given. This is opposite the Geiger Counter. -If your plate serial number is even (ending in 02, 04) orient the LEDs in the second orientation given. This is underneath the Geiger Counter. Example of an even plate serial number

70. RockOn! 2009 70 Step 6: LED Mounting [General] -Extend the wiring underneath the plate and match the red ‘x’ mounting location as shown. -Mount the blue RBF wiring and stake near the middle of the appropriate notch on your plate. -Make sure the lip of the red LED connector is flush with the edge of the plate. -The front of the green LED should be even with the edge of the notch when mounting. -Consult the following pictures of each orientation with any questions.

71. RockOn! 2009 71 LED Mounting: Odd Serial Number RockOn! 2009

72. 72 Step 6: LED Mounting: Odd Serial Number -The red LED connector goes on top of the red x as shown. Orient the lip down and flush with the edge of the plate. -Also note the positive red wire is oriented inwards for this orientation.

73. RockOn! 2009 73 Step 6: LED Mounting: Odd Serial Number -Have a partner hold the LED and RBF wiring in place. -Now hot glue the wiring in place in the same manner the photo shows. -Be careful not to burn your partner’s hand!

74. RockOn! 2009 74 Step 6: LED Mounting [plate overview] Bottom View

75. RockOn! 2009 75 LED Mounting: Even Serial Number RockOn! 2009

76. 76 Step 6: LED Mounting: Even Serial Number -The red LED connector goes on top of the red x as shown. Orient the lip down and flush with the edge of the plate. -Also note the positive red wire is oriented outwards -Also notice the green LED is flush with the notch edge, but under the plate.

77. RockOn! 2009 77 Step 6: LED Mounting: Second Orientation -Have a partner hold the LED and RBF wiring as shown. -Now hot glue the wiring in place in the same manner the photo shows.

78. RockOn! 2009 78 Staking Components RockOn! 2009

79. 79 Step 7: Staking bottom nuts -Add hot glue to the nuts on the bottom of the plate. -Stake all nuts on the bottom of the plate using hot glue as shown in the following two pictures.

80. RockOn! 2009 80 Step 7: Staking bottom nuts Side View

81. RockOn! 2009 81 Step 7: Staking bottom nuts

82. RockOn! 2009 82 Step 8: Staking the AVR -Add hot glue across the AVR as shown for extra structural security.

83. RockOn! 2009 83 Step 8: Staking the AVR Side View

84. RockOn! 2009 84 Step 9: Staking connectors -Ensure all connectors are attached in the correct orientation. -Add generous amounts of hot glue to pot the connectors to the AVR PCB. -Now the wiring is mounted solidly to the AVR PCB. Example Connector

85. RockOn! 2009 85 Step 9: Staking connectors Example Connector

86. RockOn! 2009 86 Step 9: Staking connectors

87. RockOn! 2009 87 Step 10: Staking Geiger Wires -Stake the soldering location of the Geiger wires on the Geiger PCB as shown.

88. RockOn! 2009 88 Step 10: Staking Geiger Wires

89. RockOn! 2009 89 Step 11: Staking AVR Wires -Stake the soldering location of the AVR wires on the AVR PCB as shown.

90. RockOn! 2009 90 Step 12: Staking Accelerometer Nuts -Add hot glue to the Accelerometer nuts as shown. -You may also add hot glue to the wire leads of the Z-axis accelerometers if you desire.

91. RockOn! 2009 91 Step 13: Staking Battery Bracket -Add hot glue to the areas shown on the battery bracket and connectors.

92. RockOn! 2009 92 Step 13: Staking G-switch nuts -Add hot glue to the nuts on the G-switch as shown.

93. RockOn! 2009 93 Step 14: Staking G-switch weights Before Staking

94. RockOn! 2009 94 Step 14: Staking G-switch weights After Staking [back view]After Staking [front view]

95. RockOn! 2009 95 Final Check RockOn! 2009

96. 96 Bottom of an odd plate Staking should occur at all of these places!!

97. RockOn! 2009 97 Top of an odd plate - Staking should occur at all of these places!!! - Set the completed Plate on the ESD mat and wait for further instructions.

98. RockOn! 2009 98 Congratulations! You are ready for Canister Integration RockOn! 2009