HT Controller : Assembly

Installing the various components to get the HT controller to work was probably my favorite part of the build.  Something satisfying about seeing everything coming together.  At a high level these are the key components:

Arduino : Brains of the operation

Custom circuit board : Connections out from arduino and 5v power regulation

Relays : control each of the 2 outlets (cable modem and router)

Scavanged switching power supply : 120v ac to 12v dc

DB9 : connection out to the power strip where a relay controls each of 6 outlets/amps

So everything was installed on nylon spacers, with small machine bolts coming up through the bottom.  That can be seen well on the relay installation:

And here is the custom circuit board I created in my isolation routing tutorial.  All wired up to the front panel, buttons, db9, and relays:

Overall unit in early assembly:

And (almost) final:

Primary lesson learned on this assembly was when routing a circuit board that you are going to attach ribbon cables to, ensure the holes are lined up straight.  Do not stagger them as I did, it makes it very difficult.

I also learned that when soldering to plain copper boards you really need Flux – more than than what is in your solder.  I had good luck with some acid-based plumbers flux I had laying around.  I put that on the board where the pads where, and then tinned them.  Don’t forget to clean it of with rubbing alchohol or acetone.

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