DIY-Thermocam Assembly Guide Batch 5

1. To assemble the device, you need the following tools: A soldering

iron, some solder, a gripper, a nippers and a screwdriver
2. If you have the choice between multiple soldering tips, use the
smallest one.
3. In case you have a soldering station with adjustable temperature, use
around 400 degree celcius
4. Unpack all the components from the box
5. Catch the PCB, the microcontroller and one of the two header strips
6. Cut the header strip with a gripper into the following pieces: 2 x 14, 1
x 5 and 1 x 1

DIY-Thermocam Assembly Guide Batch 5

Page 1

1. Plug the microcontroller into the header pieces

2. The one single header should be placed in the hole labeled VUSB, do
not forget it
3. The two long stripes with 14 pins go into the left and right side, the 5
pin header should be placed at the end
4. If the 5 pin header does not fit in, cut the overlapping plastic parts on
its edges
5. Put them into the PCB and make sure they sit tight, otherwise the
cutout in the enclosure will not match
6. Solder the pins on the top of the microcontroller

DIY-Thermocam Assembly Guide Batch 5

Page 2

1. Turn the PCB around, make sure the microcontroller still sits tight
2. Solder the pins on the bottom
3. Remove the overlapping pieces with a gripper
4. Re-solder the pins to make sure they are really connected well to the
PCB

DIY-Thermocam Assembly Guide Batch 5

Page 3

1. Catch the five resistors from the mixed parts bag

2. There are two different kinds of resistors: 10K & 4.7K, they need to
be soldered into the right position marked with the corresponding label
3. The color code for the three 10K resistors starts with brown-black,
they should go to the right
4. For the two 4.7k resistors, the color code starts with yellow-purple,
they should go to the left
5. Solder them into the PCB and cut the overlapping wire pieces on the
backside
6. Then solder the transistor and do the same with the overlapping
pieces

DIY-Thermocam Assembly Guide Batch 5

Page 4

1. Take the coin cell holder and solder it into the two holes on the top left
side of the PCB
2. Remove the coin cell battery from its packaging and insert it into the
holder, so that the side with the +-marker is on the top

DIY-Thermocam Assembly Guide Batch 5

Page 5

1. The next step is to solder the step-up converter to the PCB

2. Cut a piece of three pins from the header strip and solder it to the
PCB
3. Then solder the converter board to the header and cut the overlapping
pins

DIY-Thermocam Assembly Guide Batch 5

Page 6

1. Cut one of the remaining pin headers into the following pieces: 1 x 3
and 4 x 1
2. Then plug the pins into the PCB and stack the lithium charging
module on top
3. Finally, solder both sides and remove the overlapping header pieces
on the backside

DIY-Thermocam Assembly Guide Batch 5

Page 7

1. Catch the MLX90614 single-point infrared sensor

2. Plug it into the board, make sure the little indicator matches the mark
on the PCB
3. Solder one pin first on the backside
4. Then push the sensor against the board while heating the solder on
the same pin to make sure that the sensor is really soldered flat to the
board
5. Solder the remaining three pins on the backside
6. Remove the overlapping header pieces with a gripper

DIY-Thermocam Assembly Guide Batch 5

Page 8

1. Catch the Lepton board and remove the Lepton from it by pulling it out
carefully
2. Put the removed sensor back into the plastic bag, so that it is stored
safe for the rest of the assembly procedure

DIY-Thermocam Assembly Guide Batch 5

Page 9

1. Grab the 8-pin right-angle female header and solder it into the PCB
2. Solder one pin first, then make sure it sits really tight
3. Solder the remaining seven pins
4. Use two M2x10 bolts (the longer ones) and put one of the smaller
black spacers on top of each
5. Please note that there are 10 black spacers, but only two of them are
bigger than the others

DIY-Thermocam Assembly Guide Batch 5

Page 10

1. Plug the Lepton board into the socket

2. Save the two bolts with two plastic nuts
3. Pick up two more M2x10 bolts and put them into the empty holes on
the top
4. Use two more smaller black spacers and put them between the PCB
and the Lepton module, next to the two bolts on the top
5. Use two more plastic nuts and save the remaining two bolts
6. Make sure all four nuts sit really tight and the module is collateral /
parallel to the PCB

DIY-Thermocam Assembly Guide Batch 5

Page 11

1. Catch four M2 x 10 bolts, two of the smaller black spacers and two of
the larger spacers
2. Push the four bolts throught the holes inside the PCB from the bottom
side
3. For the two bottom screws, use the larger spacers
4. For the top ones, use the smaller spacers

DIY-Thermocam Assembly Guide Batch 5

Page 12

1. Take the camera module and put it on top of the four screws
2. Safe it with four plastic nuts and tighten them
3. Solder the four pins on the backside to the PCB

DIY-Thermocam Assembly Guide Batch 5

Page 13

1. Catch one of the two 3-pin female headers and solder it into the PCB,
then remove the overlapping pieces
2. Take the two remaining M2 x 10 bolts and spacers
3. Take the laser modul and stack the second 3-pin female header into
its soldered pins
4. You may want to bend the pins on the side a little bit to the left and
right, so that it will have a better stay
5. Secure the laser module with one plastic nut on top of each screw and
make them fit tight

DIY-Thermocam Assembly Guide Batch 5

Page 14

1. Solder the charging LED to the place labeled CHG-LED with the short
leg in the hole G
2. Bend the LED to the top as shown on the image
3. Solder the battery connector to the place labeled LIPO on the right
side
4. On the left side, solder the display connector in the 40 holes, make
sure it really sits tight

DIY-Thermocam Assembly Guide Batch 5

Page 15

1. Remove the protection foil from one side of the adhesive tape and
push it again the PCB
2. Remove the protection foil on the other side and push the battery on
top of it in the position shown
3. The circuit board on the battery has to be on the right side, otherwise
there may be problems
4. Do not plug in the battery into the connector, we will do this later

DIY-Thermocam Assembly Guide Batch 5

Page 16

1. Take the push button, the power switch and the external USB switch
together with the shrink tubes and the cable pieces
2. Solder the cable pieces to the components by using the shortes two
for the power switch, the middle ones for the button and the longest
three for the USB switch
3. Put the shrink tubes on top of the cables by using the smallest three
ones for the USB switch, the middle two for the button and the biggest
two tubes for the power switch
4. Heat the tubes with the soldering iron to make them shrink

DIY-Thermocam Assembly Guide Batch 5

Page 17

1. Grab the three shown sidepanels and remove the protection foil from
both sides
2. Put the position of the power switch to OFF (O) and push it through
the hole in the panel
3. Secure the USB power switch with two M2 x 8 bolts and two nuts,
then switch it to the upper position as shown on the image
4. On the next panel, fix the tripod socket with three M2 x 8 bolts, three
washers and nuts and screw them very tight
5. On the right panel, put the button into the other side of the sidepanel
and safe it with the screw ring

DIY-Thermocam Assembly Guide Batch 5

Page 18

1. Solder the wires of the push button to the two pins labeled BUTTON,
the direction does not matter
2. Next, solder the wires of the power switch to the two pins labeled
SWITCH, the direction does not matter
3. Last, solder the three wires of the external USB switch to the
connection labeled EXT-POWER
4. Take care to keep the chronology order, so top to top, middle to
middle, bottom to botttom

DIY-Thermocam Assembly Guide Batch 5

Page 19

1. Make sure the power switch is still in the off-position, then connect the
battery to the connector
2. Put the two sideplates to their position and bend the wires, so that
they do not put the display under pressure later

DIY-Thermocam Assembly Guide Batch 5

Page 20

1. Pick the display module and insert the microSD card into the slot on
the bottom
2. Screw the four smaller distance bolts into the four standoffs

DIY-Thermocam Assembly Guide Batch 5

Page 21

1. Put the display module on top of the PCB and safe it with the four
remaining, longer distance bolts
2. Screw them into the PCB as shown on the image and tighten them

DIY-Thermocam Assembly Guide Batch 5

Page 22

1. Remove the protection foil from the remaining enclosure parts and
also from the display itself
2. Install the display panel and afterwards the right and bottom sidepanel
3. Insert the Lepton back into the module and put the laser in an upright
position
4. Make sure that the microUSB connector snaps into the hole of the left
sidepanel

DIY-Thermocam Assembly Guide Batch 5

Page 23

1. Put the backpanel on top of the four sidepanels and secure it with four
of the black screws
2. It may be a little bit tricky to make it fit the first time, do not use more
pressure than required

DIY-Thermocam Assembly Guide Batch 5

Page 24

1. Use the remaining four black screws and put them into the holes on
the front plate, then tighten them

DIY-Thermocam Assembly Guide Batch 5

Page 25

1. If you want to charge the device over the USB port, make sure the
external USB switch is on the top position
2. The charging LED lights up red as long as the battery is charged,
when fully charged, it will turn green
3. In case you want to use the internal battery to supply an external
device with power from the USB port (f.ex. the video output module),
put the USB switch to the bottom position as shown on the image
4. For normal operation, always leave the external USB switch on the
top position
5. You can now turn the device on with the power switch and will see the
first-start screen
6. Check out the manual and the various how-to guides for more
information about the device usage
7. In case there appears a diagnostic screen on the first start, please
use the contact formulor and send the error message

DIY-Thermocam Assembly Guide Batch 5

Page 26