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Insert the IR detector on the same side as the switches, and solder the three leads on the
other side of the controller PCB. You can set the height perfectly by temporarily placing
C2 underneath the IR detector. The spacing isn’t critical, but if you set it too high off the
board, it will bump into the IR window in the front panel. The top surface of the IR
detector should be about 0.3” off the PCB.
Install the LEDs
Figure 27-LED with white spacer added
This section is a little tricky, so please follow the instructions carefully for best results.
Getting the LED’s straight and true will allow you to insert the front panel PCB into the
chassis (in a later step) with a minimal amount of swearing.
1. Mate each of the 15 LED’s with a plastic spacer as shown in Figure 27. These
spacers make it easy to assure uniform height above the PCB.
2. LED polarity matters! There are two ways to see the polarity:
a. If the leads are uncut, you’ll see the cathode lead is shorter than the anode
lead.
b. If the leads are cut, you can see the difference in the shape of the metal
lead-frame inside the green plastic of the LED (Figure 27).
3. Observe this procedure for each LED that you install:
a. Verify the polarity and insert an LED into the PCB.
b. Make sure the bottom of each LED touches the white spacer evenly. Make
sure that the other side of the white spacer sits on the PCB.
c. Solder just one lead to the PCB.
d. Inspect your work to make sure that the white spacer sits flat on the PCB.
If it doesn’t, then it’s easy to heat the one solder joint while pushing the
LED assembly against the PCB. Once it moves to flush with the PCB,
then remove your soldering iron.
e. Inspect the result to see that the LED/space combination is flat against the
board and level.
f. Once the LED is at the correct height, you can solder the second lead.
g. You may find it’s easier to solder the second lead if you cut the first,
already soldered lead to about ¼” protrusion through the PCB.
Important! Install all the LEDs, D1-D15 with the same orientation!
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