Orient the jig so that the 3/64” holes
are at the top and bottom of the jig facing
you. Each layer is made up of 16 LEDs.
Put two C shaped tin wires in place
along the four 3/64” holes (Figure 20). The
small bent sections of each tin wire should
go inside the 3/64” holes. The orientation
of each tin wire is such that it is
perpendicular to the anode lead’s
horizontal lines and is vertical to you.
Insert the bent LEDs upside down
into the top right corner 7/32” hole
(Figure 21). The LED should be
oriented such that the bent anode lead
(which rests parallel with the jig
surface) is along the horizontal line
parallel to you. Insert a second LED
into the hole to the left of the previous
one using the same orientation. Repeat
this process for the rest of the LEDs.
There are 16 7/32” holes. When all 16
LEDs are inserted (for each row of four
LEDs), their bent anode leads should
overlap some and form a horizontal
line. The LEDs are soldered together at
the overlaps as shown in Figure 22.
Solder the overlapping anode
portions; there is a total of 12 solder
joints. Solder the LED leads quickly since a longer contact period between the
solder iron and the leads could damage the LED. Also remember to solder the
eight solder joints where the two tin wires overlap the four horizontal anode lead
lines. When you are finished, the LED layer may be removed from the jig (Figure
23). Cut off the extra portion of tin wire that went into the 3/64” holes (Figure 24).
At this point, test the LEDs in the completed layer. To do so, touch the positive
terminal to the uncut common anode lead on the right and the negative terminal to
the upwardly bent cathodes one by one. Continue building three more layers in the
same manner. Lift the layers from the jig carefully by pulling the bent cathode leads
Notice in Figure
25 on the right-hand
side of the layer that
we have four
leads. Each layer only
needs one extended
anode lead. Each
layer differs from
another in terms of
the position of the
uncut common anode
layer lead; this is how
we will be referring to
the different layers
from now on. Arrows
in Figure 26 indicate
the uncut common anode layer leads.
Figure 20. Jig base with two tinned
Figure 22. Layer 0’s LEDs loaded into the jig
base; red circles show the solder joint points.
Figure 21. Jig base with two tinned
wires and the first LED loaded.
Figure 23. Layer 0 soldered and removed
from the jig.
Figure 24. Clipping the ends of the
common anode wires.
Figure 25. Bottom view of the
Figure 26. Bottom view of four layers, showing the
extended anode lead for each layer.
48 August 2011