1. Uvod

1. Introduction

This manual provides step-by-step instructions for assembling the 5AQ Clonebox. The device consists of a 3D-printed enclosure, an Arduino Uno R3 controller, an MCP2515 CAN-bus module, a DC-DC converter, an OBD-II breakout, a MiniWiggler debugger, a 16×2 I2C LCD display, and a rocker switch. It is designed to be assembled by technicians familiar with soldering and working with low-voltage and mains power. Follow these instructions carefully to ensure safe and reliable operation.

Ovaj priručnik pruža korak-po-korak upute za sastavljanje uređaja 5AQ Clonebox. Uređaj se sastoji od 3D-printanog kućišta, kontrolera Arduino Uno R3, modula MCP2515 za CAN-bus, DC-DC pretvarača, OBD-II konektora, MiniWiggler programatora, 16×2 I2C LCD zaslona i prekidača tipa rocker. Namijenjen je tehničarima koji imaju iskustva s lemljenjem te radom na niskonaponskim i mrežnim instalacijama. Pažljivo slijedite upute kako bi uređaj radio sigurno i pouzdano.

2. Sigurnosne informacije

2. Safety Information

• Work in a well-ventilated area and use personal protective equipment when soldering.
• Disconnect the assembly from AC power before working on any wiring.
• Double-check all connections before connecting power.
• Use only the recommended wire gauges (28 AWG for signal wiring and 16 AWG for mains wiring).
• Observe polarity; reversing 12 V or 5 V lines may damage the electronics.

• Radite u dobro prozračenom prostoru i koristite osobnu zaštitnu opremu tijekom lemljenja.
• Prije rada na ožičenju odspojite sklop od mrežnog napajanja.
• Dvaput provjerite sve veze prije spajanja napajanja.
• Koristite samo preporučene presjeke vodiča (28 AWG za signalne vodove i 16 AWG za mrežne vodove).
• Obratite pozornost na polaritet; obrnutim spajanjem 12 V ili 5 V možete oštetiti elektroniku.

3. 3D-printani dijelovi

3. 3D-printed parts

The enclosure and jigs are printed from PET-G (e.g., Devil Design PET-G galaxy black). Remove the support material carefully after printing and save some pieces to use later as shims.

Kućište i pomagala ispisani su od PET-G materijala (npr. Devil Design PET-G galaxy black). Nakon ispisa pažljivo uklonite potpornu strukturu i sačuvajte dio materijala za kasniju uporabu kao podloške.

• 5AQ-guide-for-pogo-pins-pt1.step
• 5AQ-guide-for-pogo-pins-pt2.step
• 5AQ-label-Tag.step
• 5AQ-closer-window.step
• 5AQ-Top.step
• 5AQ-Bottom.step
• 5AQ-Top-Slider.step

4. Elektroničke komponente

4. Electronics components

The following components and materials are required to assemble the device. Links to distributors are provided for reference.

Za sastavljanje uređaja potrebne su sljedeće komponente i materijali. Poveznice na distributere navedene su za referencu.

5. Priprema elektronike

5. Preparing the electronics

Back to Top

5.1 Rocker switch wiring

Back to Top

5.1 Ožičenje prekidača

Refer to Figure 5.1 to prepare the illuminated rocker switch. Solder 28 AWG wires according to the indicated colours and lengths. A 1 kΩ resistor is soldered in series with the red lead for the LED.

Pogledajte sliku 5.1 kako biste pripremili osvijetljeni prekidač. Zalemite žice debljine 28 AWG prema prikazanim bojama i duljinama. Na crveni vod za LED zalemi se otpornik od 1 kΩ.

Back to Top

5.2 LCD display wiring

Back to Top

5.2 Ožičenje zaslona

Trim a 4-conductor 28 AWG cable to 16.5 cm. Solder the wires to the pins on the I²C board mounted on the LCD: black to GND, red to +5 V, green to SDA (A4), and yellow to SCL (A5).

Odrežite četveropinski kabel 28 AWG na duljinu 16,5 cm. Zalemite žice na I²C pločicu na LCD-u: crna na GND, crvena na +5 V, zelena na SDA (A4), a žuta na SCL (A5).

Back to Top

5.3 TE connector wiring

Back to Top

5.3 Ožičenje TE konektora

Cut two twisted pairs of 28 AWG wires: red/black at 40 cm and yellow/green at 45 cm (limit 25 cm inside the enclosure). The wires are inserted into the TE connectivity housing as shown in Figures 5.3a-5.3d. Ensure the orientation of CAN H (yellow), CAN L (green), 12 V (red) and GND (black).

Izrežite dva upletena para žica 28 AWG: crvena/crna 40 cm i žuta/zelena 45 cm (ograničenje 25 cm unutar kućišta). Žice se umeću u TE kućište kao na slikama 5.3a-5.3d. Pazite na orijentaciju CAN H (žuta), CAN L (zelena), 12 V (crvena) i GND (crna).

Back to Top

5.4 MiniWiggler preparation

Back to Top

5.4 Priprema Miniwigglera

Remove the two white LEDs from the MiniWiggler board and solder wires to the exposed pads as shown in the figures. Prepare a cable harness matching the colour code (see the hand-drawn pinout) and assemble the connector as shown.

Uklonite dvije bijele LED diode s pločice MiniWigglera i zalemite žice na otkrivena mjesta kako je prikazano na slikama. Pripremite kabelski snop prema prikazanom kodu boja (vidi ručno nacrtan raspored pinova) te sastavite konektor.

Back to Top

5.5 AC inlet wiring

Back to Top

5.5 Ožičenje AC ulaza

Solder two 16 AWG silicone wires (8 cm each) to the C8 panel-mount AC inlet as shown in Figure 5.5. Insulate the joints with heat-shrink tubing.

Zalemite dvije silikonske žice presjeka 16 AWG (duljine 8 cm) na C8 panelni AC ulaz prema slici 5.5. Lemove zaštitite bužirima za toplinsko skupljanje.

Back to Top

5.6 OBD-II connector wiring

Back to Top

5.6 Ožičenje OBD-II konektora

Insert the red (12 V), green (CAN L), yellow (CAN H) and black (GND) wires into the OBD-II connector housing (179631-1) in the positions shown in Figures 5.6a-5.6c. Crimp the appropriate pins (776001-1) and insert them until they latch.

Umetnite crvenu (12 V), zelenu (CAN L), žutu (CAN H) i crnu (GND) žicu u OBD-II kućište (179631-1) na položaje prikazane na slikama 5.6a-5.6c. Na žice zakrimpajte odgovarajuće kontakte (776001-1) te ih umetnite do zadrške.

Back to Top

5.7 CAN-bus harness assembly

Back to Top

5.7 Sastavljanje CAN-bus kabela

Prepare short coloured wires according to the lengths indicated in Figure 5.7a and solder them between two 8-pin headers to create an adapter cable. Map the wires so that the Arduino UNO pins (8, 10, 11, 12, 13) connect to INT, CS, SI, SO and SCK on the MCP2515 module, and include 5 V and GND. The finished harness is shown in Figure 5.7b.

Pripremite kratke žice u boji prema duljinama navedenim na slici 5.7a te ih zalemite između dva 8-pinska konektora kako biste izradili prilagodnik. Povežite žice tako da pinovi Arduino UNO (8, 10, 11, 12, 13) idu na INT, CS, SI, SO i SCK na modulu MCP2515, te dodajte 5 V i GND. Gotovi kabel prikazan je na slici 5.7b.

6. Sklapanje kućišta

6. Enclosure assembly

After preparing all electronic subassemblies, assemble the 3D-printed parts and install the electronics.

Nakon pripreme svih elektroničkih podsklopova, sastavite 3D-printane dijelove i ugradite elektroniku.

Back to Top

6.1 Removing support material

Back to Top

6.1 Uklanjanje potpornog materijala

Carefully remove the support structures from the printed top and bottom panels. Keep some of the removed supports for use as shims later.

Pažljivo uklonite potpornu strukturu (support material) s ispisanih gornjih i donjih ploča. Dio uklonjenog materijala sačuvajte za kasniju uporabu kao podloške.

Back to Top

6.2 Installing label and top slider

Back to Top

6.2 Ugradnja oznake i gornjeg klizača

Glue the label tag into the recessed slot on the top panel and insert the top slider into its track as shown in Figure 6.2. Use a small amount of plastic adhesive and allow it to cure.

Umetnite pločicu s oznakom u udubljeni utor na gornjoj ploči te umetnite gornji klizač u njegovu stazu kao na slici 6.2. Upotrijebite malu količinu ljepila za plastiku i pustite da se osuši.

Back to Top

6.3 Installing the window closer

Back to Top

6.3 Ugradnja zaklopke prozora

Install the window closer into the rectangular cut-out on the underside of the top panel. Use a soldering iron to weld the plastic tabs through the panel to hold it in place, as shown in Figure 6.3.

Umetnite zaklopku prozora u pravokutni otvor na donjoj strani gornje ploče. Pomoću lemilice rastalite plastične jezičke kroz ploču kako biste ih učvrstili, kao na slici 6.3.

Back to Top

6.4 Installing pogo pin guides

Back to Top

6.4 Ugradnja vodilica za pogo pinove

Attach the green pogo-pin guide parts to the underside of the top panel using the saved support material as shims. The jig ensures that the pogo pins are aligned properly.

Pričvrstite zelene vodilice pogo pinova na donju stranu gornje ploče koristeći sačuvani potporni materijal kao podloške. Kalup osigurava pravilno poravnanje pogo pinova.

Back to Top

6.5 Installing pogo pins

Back to Top

6.5 Umetanje pogo pinova

Apply a small drop of cyanoacrylate (super glue) to each pogo pin and insert the pins into the pre-drilled holes on the top panel. Make sure the pins are aligned vertically using the green jig. If the holes are too tight due to printing tolerances, widen them slightly with a 1.5 mm drill bit.

Nanesi malu kap cijanokrilatnog ljepila (super ljepila) na svaki pogo pin i umetni pinove u prethodno izbušene otvore na gornjoj ploči. Poravnaj pinove okomito uz pomoć zelenog kalupa. Ako su rupe preuske zbog tolerancije ispisa, lagano ih proširi svrdlom promjera 1,5 mm.

Back to Top

6.6 Installing the display, switch and LEDs

Back to Top

6.6 Ugradnja zaslona, prekidača i LED-ica

Insert the 16×2 LCD module from below, align it with the rectangular window on the top panel and secure it with hot glue. Insert the rocker switch into its round opening, ensuring the tabs snap into place. Mount the two white LEDs into their slots; orient each LED so that the longer anode lead (+) faces outward, then fill the cavity with hot glue to insulate and hold them in place.

Umetnite 16×2 LCD modul odozdo, poravnajte ga s pravokutnim prozorom na gornjoj ploči i učvrstite vrućim ljepilom. Umetnite prekidač tipa rocker u okrugli otvor tako da se zalisci zabrave. Postavite dvije bijele LED-ice u njihove utore; okrenite svaku LED-icu tako da dulja anoda (+) gleda prema van, a zatim utor ispunite vrućim ljepilom kako biste izolirali i učvrstili LED-ice.

Back to Top

6.7 Completing the top assembly

Back to Top

6.7 Završetak gornjeg sklopa

After installing the pogo pins, display, switch and LEDs, the top panel should resemble the assembly shown in Figure 6.7. Double-check that all components are secure and that the pogo pins are flush with the surface.

Nakon ugradnje pogo pinova, zaslona, prekidača i LED-ica, gornja ploča treba izgledati kao na slici 6.7. Provjerite jesu li sve komponente učvršćene i jesu li pogo pinovi u ravnini s površinom.

Back to Top

6.8 Routing the TE connector harness

Back to Top

6.8 Provođenje TE kabela

Feed the pre-assembled TE connector harness through the rectangular slot in the side of the bottom enclosure. Leave about 25 cm of cable outside the enclosure for external connection and secure the harness inside with a zip tie to prevent the cable from being pulled out.

Provucite prethodno sastavljeni kabel TE konektora kroz pravokutni otvor na bočnoj strani donjeg kućišta. Ostavite oko 25 cm kabela izvan kućišta za vanjsko spajanje i osigurajte kabel unutra vezicom kako se ne bi mogao izvući.

Back to Top

6.9 Installing the USB-B panel mount

Back to Top

6.9 Ugradnja USB-B priključnice

Insert the USB-B panel-mount connector (CP30607NX) into the small rectangular slot in the bottom enclosure. The flexible retention clip should face the right side of the enclosure. Apply a small amount of cyanoacrylate around the edges to hold it in place. To support the MiniWiggler board later, glue a piece of the removed support material to the inside of the enclosure behind the USB connector.

Umetnite panelnu USB-B priključnicu (CP30607NX) u mali pravokutni utor u donjem kućištu. Savitljiva kukica za zadržavanje treba biti okrenuta prema desnoj strani kućišta. Nanesite malu količinu cijanokrilatnog ljepila oko rubova kako biste je učvrstili. Za oslonac Miniwiggler ploče kasnije, zalijepite komadić uklonjenog potpornog materijala na unutarnju stranu kućišta iza USB priključnice.

Back to Top

6.10 Installing remaining components and the AC-DC converter

Back to Top

6.10 Ugradnja preostalih komponenti i AC-DC pretvarača

Place the Arduino UNO R3 (pre-programmed), the MCP2515 CAN-bus module and the AC-DC converter onto their respective standoffs in the bottom enclosure as illustrated in Figures 6.10a and 6.10b. Secure the AC-DC converter with hot glue to prevent vibration. Connect the white 16 AWG silicone wires from the C8 inlet to the input of the converter; connect the converter’s 12 V output to the prepared harness.

Postavite Arduino UNO R3 (prethodno programiran), MCP2515 CAN-bus modul i AC-DC pretvarač na njihove oslonce u donjem kućištu kao na slikama 6.10a i 6.10b. Učvrstite AC-DC pretvarač vrućim ljepilom kako biste spriječili vibracije. Spojite bijele silikonske žice 16 AWG s C8 ulaza na ulaz pretvarača; izlaz pretvarača od 12 V spojite na pripremljeni kabelski snop.

Back to Top

6.11 Installing the OBD-II connector

Back to Top

6.11 Ugradnja OBD-II konektora

Insert the white OBD-II panel-mount connector into its slot in the bottom enclosure. Because the printed plastic may contract after cooling, preheat the slot gently with a hot-air gun to reduce stress and prevent cracking. Push the connector into place until it clicks.

Umetnite bijeli OBD-II panelni konektor u njegov utor u donjem kućištu. Budući da se isprintana plastika može skupiti nakon hlađenja, prethodno zagrijte utor vrućim zrakom kako biste smanjili naprezanje i spriječili pucanje. Utisnite konektor na mjesto dok ne sjedne.

Back to Top

6.12 Securing Arduino and CAN-bus boards

Back to Top

6.12 Učvršćivanje Arduina i CAN-bus modula

After positioning the Arduino UNO and MCP2515 module, melt the tops of the plastic standoffs with a soldering iron to lock the boards in place. This technique provides mechanical retention without screws.

Nakon postavljanja Arduino UNO i MCP2515 modula, rastalite vrhove plastičnih oslonaca lemilicom kako biste pričvrstili pločice. Ova tehnika osigurava mehaničko zadržavanje bez vijaka.

Back to Top

6.13 Wiring connections

Back to Top

6.13 Spajanje ožičenja

Once all components are installed, connect the wiring harnesses according to the wiring diagram (Figure 6.13). Keep the wires neat and avoid crossing signal and power lines.

Kada su sve komponente ugrađene, spojite kabelske snopove prema shemi spajanja (slika 6.13). Održavajte žice urednima i izbjegavajte križanje signalnih i napojnih vodova.

Back to Top

6.14 Securing the MiniWiggler and wiring LEDs

Back to Top

6.14 Učvršćivanje Miniwigglera i ožičenje LED-ica

Connect the MiniWiggler into the USB-B connector. Use a cable tie or a dab of silicone adhesive to hold the board securely against the support. Connect the two LED wires (from the removed LEDs) to the MiniWiggler pads; use heat-shrink tubing to insulate the joints. Route the harness according to the colour code diagram.

Spojite MiniWiggler na USB-B priključnicu. Upotrijebite vezicu ili malo silikonskog ljepila kako biste pločicu učvrstili uz oslonac. Spojite dvije žice LED-ica (od uklonjenih LED-ica) na kontaktne točke Miniwigglera; upotrijebite bužire za izolaciju. Provedite kabelski snop prema dijagramu kodova boja.

Back to Top

6.15 Final internal view and closing the enclosure

Back to Top

6.15 Završni pogled iznutra i zatvaranje kućišta

Verify that all connections follow the wiring diagram and that wires are neatly arranged. The completed internal assembly should resemble Figure 6.15a. Once satisfied, place the top panel onto the bottom enclosure and secure the two halves using screws, clips or melted pegs. The finished device is shown in Figure 6.15b.

Provjerite jesu li sve veze u skladu sa shemom spajanja i jesu li žice uredno posložene. Dovršeni unutarnji sklop treba izgledati kao na slici 6.15a. Kad ste zadovoljni, postavite gornju ploču na donje kućište i učvrstite dvije polovice vijcima, kopčama ili topljenim klinovima. Gotov uređaj prikazan je na slici 6.15b.

7. Završne provjere

7. Final checks

• Use a continuity tester to ensure there are no short circuits.
• Power the unit from a current-limited supply and monitor the voltage levels.
• Verify that the LCD display powers on and that the CAN-bus communication functions correctly.

• Provjerite nema li kratkih spojeva uz pomoć ispitivača kontinuiteta.
• Uključite uređaj preko izvora napajanja s ograničenom strujom i pratite naponske razine.
• Provjerite da se LCD zaslon uključuje i da CAN-bus komunikacija ispravno radi.