Start Box v1.0 (rev 0)

Startbox V1.0 rev-0 2015

limited edition (1-15)

Safety

Safety always comes first!

Power

NEVER connect to mains source
NEVER use powersources connected to mains

Polarity

Wrong polarity can lead to critical malfunction!
e.g. the leds don't go on, but circuit will be active!
there is no protection built in against wrog polarity!
Please keep that in mind esp when e.g. using external batteries

Batteries

ONLY use batteries from 6-12 Volt
Do NOT use 9V block batteries.
they are unreliable and can fail easily as they are not designed for high current.
ONLY use batteries designed for high current and capacity (non rechargeable alkaline batteries are ok)
Do NOT use NiMH or Lithtium (neither LiIo or LiPo) batteries.
They will wear out and break quickly.
NiCd or PB is best choice for reliability when useng rechargeable batteries e.g. for use with self made copperwire ignitors.

Operating

When operating on the rocket ensure:

The box is powered off
Cables are disconnected
Key is removed
- you carry the key!

Technical Details

the startbox is designed for safe operation and fullfills the following requirements:

operation voltage: 6-12V (high capacity/current batteries only)
key switch
shortcircuit ignition line
check ignition circuit
test current <50mA
ignition line diameter >= 1.5mm²

Funktionsweise / How it works

after powering on and turning the key switch (arm switch in off position) the ignitor lines are short circuited to create a potential free environment and prevent misfire due to electrostatic charges.
if the arm switch is moved to up position a test circuit is activated and sends a small current through the ignition line
- the test current is limited to ~ <50mA in total using a ultralow current led and a low current piezo buzzer to ensure a maximum test current of < 50mA
- the yellow led right above the arm switch indicates the box is armed.
- the red circuit test led is placed above the start button and should light up if the circuit is ready for operation and ignitor is connected properly. also the buzzer is start beeping.
if start button is pressed the ignitor will be fired using all current available limited by the fuse.
after successful ignition the start led and buzzer go off.

PCB

designed by kalle/raketenclub
produced by liteon
limited to 35pcs (v1r0 2015)

Connections

component to pcb connections

arm switch / sicherungsschalter

arm switch, 9-polig SWA
SWA = Arm Switch / Sicherheits-Schalter

Pin Layout, Top view:
ON / OUT1	1	4	7
IN	2	5	8
ON / OUT2	3	6	9

Pin	Name	color			connects to the PCB on:
1	`SWA1`	black	……….	→	`P21`
2	`SWA2`	grey	……….	→	`P33`
3				→	not connected
4	`SWA4`	green	……….	→	`P30`
5	`SWA5`	black	……….	→	`P22`
6	`SWA6`	yellow	……….	→	`P32`
7				→	not connected
8	`SWA8`	blue	……….	→	`P39`
9	`SWA9`	yellow/green	…….…	→	`P34`

led

Component	Name	Color			colored cable connects to the PCB on:		black cable connects to the PCB on:
Power LED	`LP`	red	…..	→	`P5`	`LP+`	`P19`	`LP-`
Key Switch LED	`LK`	red	…..	→	`P10`	`LK+`	`P20`	`LK-`
Arm LED (safe position)	`LSA`	green	…..	→	`P13`	`LSA+`	`P29`	`LSA-`
Arm LED (armed position)	`LAR`	yellow	…..	→	`P12`	`LAR+`	`P31`	`LAR-`
Start LED	`LST`	red	…..	→	`P14`	`LST+`	`P38`	`LST-`

power switch

SWP

			connects to PCB on:
Power Switch	`SWP`	→	`P3` + `P4`

schluesselschalter / key switch

SWK

			connects to PCB on:
Key Switch	`SWK`	→	`P8` + `P9`

start taster/button

SWZ

			connects to PCB on:
Start Button	`SWZ`	→	`P18` + `P36`

batterie anschlusskabel / battery cable

			connects to PCB on:
BAT	`BAT+` (….. red wire)	→	`BAT +`
BAT	`BAT-` (….. black wire)	→	`BAT -`

Sicherung / Fuse

F

2,5A, keramik, träge

			connects to PCB on:
Fuse	`F`	→	`P1` + `P2`

Buzzer

BUZ

6-12V piezo buzzer

			connects to PCB on:
Buzzer	`BUZ+` (….. red wire)	→	`P11`
Buzzer	`BUZ-` (….. black wire)	→	`P37`

zuender buchsen / ignitor line sockets

Z

			connects to PCB on:
OUT	`Z+` (….. red wire)	→	`P35`
OUT	`Z-` (….. blue wire)	→	`P28`

Procedures

Power OFF

move arm switch up to safe position → left green led above arm switch lights up, right yellow led turns off
turn key left to upward position → red light above key switch turns off
remove key
move power switch down to off position → red light above power switch turns off

Power ON

ensure the box is powered off correct like described above, make sure all switches are in a safe position (off/safe)
move power switch up to on position → red light above power switch turns on
insert key
turn key right to left position → red light above key switch turns on

Test the box

connect the starter cables
shortcircuit the end of the starter cable or connect an amperemeter
→ follow power on procedure

move arm switch up to armed position and watch the current
- it should not be over >~50mA or maximum 1/10th of current needded to fire the ginitor

WARNING!

never ever press the startbutton while your meter is connected
this will kill your meter!
even if there is a 2,5A fuse inside the box, this can gracefully destroy your meters!

never ever press the startbutton when the connectors r short circuited

to test and press the startbutton connect a lightbulb or similar.

Start

→ follow the test procedure
→ follow the power off procedure
remove the key and take it with you so nobody can accidently switch on the box and press buttons etc
prepare your rocket accoring to your safety rules and procedures
connect the starter cables
before power on → double check all switches are in a 'safe' position (off/safe)
→ follow the power on procedure
shout out a countdown of at least 5 seconds → on T-3 seconds move arm switch up to armed position
- the internal buzzer will beeeeeeep if the ignitor is connected and everything is ok
- the red light above the start button will light up
to launch rocket press the start button
- the ignitor inside the rocket engine will fire
  - the red light above the start button goes off
  - the buzzer stops beeping

if nothing happens after ~5 seconds follow you safety rules to ensure misfire of the rocket (power off box, disconnect cables, wait for a few minutes)
enjoy launch
→ power off
recover rocket

Troubleshooting

box does not power on (red light above power switch stays off)
- remove panel
- check polarity of the cables.
- check batteries
- check connection from batterie to power cable and pcb
- check fuse and connection to pcb
- check connection from power switch to pcb
- check connection from led to pcb

box powers on but key switch does not work (led above key switch stays off)
- remove panel
- check connection from key switch to pcb
- check connection from led to pcb

arm switch does not work (green or yellow led not light up or neither green or yellow led lights up)
- remove panel
- check all connections from arm switch to pcb
- check connections from green and yellow led to pcb

box is powered on, armed and ignitor connected but led above startbutton does not power on and buzzer is beeping
- remove panel
- check led connection to pcb

box is powered on, armed and ignitor connected and led above startbutton lights up but buzzer is silent
- remove panel
- check buzzer connection to pcb

box is powered on, armed and ignitor connected but led above startbutton does not power on and buzzer stays silent
- move arm switch down to safe position
- power off!
- check ignitor cables
- check ignitor

Part list / Teile-Liste

the wooden box

Lindenholz
box: ca 5cm x 16cm x 16cm
deckel: ca 2cm x 16cm x 16cm
2 Kanthoelzer vormontiert mit Schrauben und Rosetten, vorgebohrt zur befestigung des Panels
2 eingelassene 3-4mm Neodym Magneten f. d. Verschluss
Nur echt mit dem roten Raketenclub Stempel :)

panel

Edelstahl V2A (1.4301), glatt, 144mm x 142mm x 1mm, gelasert und graviert, eine Gutseite

Auflage 25 Stck.

PCB / Platine

61 mm x 120 mm
Lagen: 1 - FR4, 1.55 mm - 35 μm
RoHS-konform - Lötstopp: Top: grün
Bestückungsdruck: Bottom: weiß - E-Test: nein
Kleinste Strukturen = 0.15 mm, Kleinstes Via = 0.3 mm
Warenursprung: Deutschland

mit 41 vormontierten Terminals

Auflage 35 Stck.

zuendkabel

zuender-anschlusskabel, 5m

2×1,5mm², transparent

zuenderanschlussklemmen und -stecker

anschlussstecker und krokoklemmen 2x rot stecker 2x rot stecker 2x kroko klemmen |

led

3mm, 2mA mit Fassung (Aussenreflektor)

led 3x rot low current led mit 4k7 vorwiderstand
1x gruen low current led mit 4k7 vorwiderstand
1x gelb low current led mit 4k7 vorwiderstand

power switch