USB to Serial Wiring for AT90USB Demo Hardware Build and SetupRequired Tools:1. Soldering Iron
2. Solder
3. Wire Strippers
4 Side Cutters
5. Static Wrist Strap
6. Small Jewelers Philips Screwdriver ( Same one used to open the PSP )
7. Small file, or sandpaper, or Dremmel
8. Ohm Meter to measure resistance
Note: If you need to know how to use your multimeter read my tutorial here:
https://www.acidmods.com/forum/index.php?topic=23202.0Required Parts:1. AT90USB Key Demo Board
1. Old PSP Headphone remote control
1. MAX3232CPE NOTE: Make sure this is the Maxim 2.5 volt part not the TI part
5. .01 uf ceramic capacitors
1. 16 Pin IC Socket
1. Small Piece of prototype board
1. DB9 Female Connector
3. 4 pin sockets of some kind
2. 4 pin plugs that mate to the sockets
1. Foot of 4 conductor wire.
1. 2" x 4" Case for AT90USB demo board
1. 2" x 2" Case for RS232 level converter
1. 26 to 30 guage wire wrap wire about 1 foot
1. Small Shrink tubing about 1/8 inch dia
1. Larger Shrink tubing about 1/2 inch dia
Required Software for the PSPPiKEY for the PSP with the Serial Port Patches
Level of Difficulty: ModerateHere is the schematic of the AT90USB demo board to PSP
Step One.Note: You can buy the connectors at this website if you do not
want to tear apart a remote control:
http://pc-mobile.net/pspslim.htmPrepare the Headphone/Serial Remote Cable:The Wire in the remote headphone controls is a material fiber with a single strand of
copper in it. The wire is very difficult to strip and tin to get ready for soldering.
It is much easier to use the tinned end that is already soldered inside the remote
control.
1. Turn unit over and remove the Screws from the remote control
2. Remove the case from the remote control
3. Unsolder the cable from the printed circuit board
4. Set the case and all the plastic parts aside, all you want is the cable
with the plug end on it for the PSP.
5. We are only going to use 4 wires on either the PSP 1000 or 2000 for right now
Step TwoObtain the ConnectorsYou can use any four pin miniature connectors you want. I found the connectors
that are used to connect CD Rom drives to the computer sound cards work really
well as they are very tiny and strong as well as locking. I had an old sound
card laying around and I stole the connector jacks from that. The cable that runs
from the CD Rom to the sound card has the matching plugs on each end.
If you are going to build the RS232 level converter so you can hook your AT90USB
demo board up to your PC you will need two of these cables. One to run from
the demo board to the level converter and the other to get the plug from to put
on the end of your PSP cable.
Here is a picture of the sound board I took the connectors from
Here is a picture of one of the connectors
Here is a picture of the jumper cable with connectors
Step ThreePutting the AT90USB demo board in a case:The wire wrap wiring is fragile and will not take a lot of abuse. That is
why I mounted my AT90USB demo board in a temporary case. I purchased the case
from Radio Shack and it is a perfect fit for the demo board. With the board
mounted at the top of the case it leaves room for another board underneath,
( This is where we are going to install the DC to DC converter later ).
I am sorry I did not do pictures while I was building the case but will show
closeups of the completed case.
1. Trim the case cover screw posts down about a quarter inch.
( These are the four posts with holes in them the cover screws to )
This allows the demo board to set down in the top of the case slightly
2. Take your sandpaper, or file, or Dremmel and make small notches at the
corners of your demo board so you can see the holes in the mounting posts
that you cut down.
NOTE: Make sure and blow off the demo board when you are done as you may
have ground a little copper on the demo board and you do not want
to create any shorts.
3. Note the locations of the two main connectors on the demo board. One is the
9 volt power connector and the other is the USB connector.
A. Mark your case as we are going to make some slots in the case. Make sure
you mark how far the connector set into the case and add about a 1/10 of
an inch extra.
B. Remove the demo board and set aside.
C. Cut the plastic of the case to make your cutouts for the USB and Power.
D. Take two of the connector jacks that you obtained in Step Two and mark
the case on one of the long sides so the two connectors are spaced
equally lengthwise and about half way down from the top.
( make the hole tight as these connectors are not panel mount and we
will have to superglue them in place. )
E. Cut the holes for the two connectors in the case.
4. Take the Two four pin connectors and solder about 3 inches of wire wrap
wire to each pin of the connectors and let it stand out straight
5. Insert the two connectors through the holes you made for them in the case
and push them about 1/2 the way in. Super Glue the connectors in place.
6. The pins are numbered 1 to 4 starting at the left side of the connector
looking down from the top.
7. On the left connector fold the wire down on pin 4 and curl it up so it does
not touch anything. ( We will use this wire in future tutorials from the
DC to DC converter )
8. Jumper the left connector pins 1,2,3 over to the right connector pins 1,2,3
You are now left with the four wires sticking out from the right connector.
Fold them up along the side of the case so when you insert the demo board
they are sticking up in the air.
9. Insert the demo board and hold it in place with the four screws that were
made to hold the cover in place.
( The demo board is now captured in the case and won't move. )
Note: The connector we are using on the demo board is J4 it is located next
to the Jtag connector and is numbered like so:
10.A. Pin number 1 (on the connector) is ground and we are going to hook that
to the demo board at J4 Pin 2
B. Pin number 4 (on the connector) is 3 volts and we are going to hook that
to the demo board at J4 Pin 1
C. Pin number 2 (on the connector) is tx data and we are going to hook that
to the demo board at J4 Pin 7
D. Pin number 3 (on the connector) is rx data and we are going to hook that
to the demo board at J4 Pin 6
Here is a picture of the completed unit
Step FourMaking a PSP Connector CableNote: The colors of the wires vary according to who the manufacturer that
made the remote was. We will have to find the correct wire by using
our multi meter.
1. Use these pictures if you have a PSP 1000 (Phat)
2. Use these pictures if you have a PSP 2000 (Slim)
A. Take the cable that you obtained in step one
B. Get your surplus CD Rom cable
C. Cut the wire to one end of the cable about 1 inch from the connector
D. Remove the outer jacket insulator exposing the four wires.
E. Get the two sizes of shrink tubing
1. Cut 3 1/2 inch pieces of shrink tubing small size
2. Cut 1 1 inch piece of shrink tube larger size
3. Slide the larger shrink tube over the PSP cable
F. Find the wire that comes from the psp connector ground slide one
of the small pieces of shrink tube over the wire. Solder that
to the wire that comes from the CD plug pin 1 and then shrink
the tubing.
G. Find the wire that comes from the psp connector pin 2 and slide one
of the small pieces of shrink tube over the wire. Solder that
to the wire that comes from the CD plug pin 4 and then shrink
the tubing.
H. Find the wire that comes from the psp connector TXD (transmit data)
and slide one of the small pieces of shrink tube over the wire.
Solder that to the wire that comes from the CD plug pin 2 and then
shrink the tubing.
I. Find the wire that comes from the psp connector RXD (receive data)
and slide one of the small pieces of shrink tube over the wire.
Solder that to the wire that comes from the CD plug pin 3 and then
shrink the tubing.
J. Slide the large shrink tubing over all your connections so it covers
the small shrink tubing and supports the two different cables so
they appear as one continuous cable.
The finished cable should look like this:
Step FiveRS232 Level ConverterThis level converter is used for many things.
1. You can plug in your PSP cable to the converter and by running
Hyper terminal you can see debug information that is sent when
programming the PSP.
2. It plugs into the AT90USB demo board and allows you to see debug
information that is programmed into the demo board software.
3. You can plug in most RS232 devices and control or read from them
over the RS232 port.
Schematics:http://mysite.verizon.net/restxsa0/PSP_Serial_Converter.pdfProcedure:1. Cut the proto board to fit in the 2 inch by 2 inch plastic box
2. Mount the 16 pin socket in the middle of the board
3. Wire the socket with all the caps inserted
4. Cut out the plastic box to mount the DB9 Connector at one end
5. Cut out the hole for the CD Rom audio connector
6. Attach the 4 three inch wires to the the CD Rom connector
7. Insert the CD Rom Connector 1/2 and glue with Super Glue.
8 Attach 3 three inch wires to the DB9 connector
9. Mount the DB9 Connector to the box
10.Solder the TXD,RXD, and ground wires from the DB9 to your proto board
11.Solder pin 1 of the CD Rom connector to the ground of your proto board
12.Solder pin 2 of the CD Rom connector to the TX data of your proto board
13 Solder pin 3 of the CD Rom connector to the RX data of your proto board
14.Solder pin 4 of the CD Rom connector to the Power of your proto board
Optional you can hook a led and resistor across the power and ground so
you can see when the PSP is powering the RS232 Level converter.
15.Plug the chip into the socket making sure you place it in the correct
direction.
Here is a picture of a completed interface:
Note: The green over the CD Rom connector is a panel mount led lamp
Note: The extra connector over the DB9 is power in so I can use this
interface on other projects.
Conclusion: This concludes the hardware part of interfacing the AT90USB demo board
to the PSP. In the next part we will go over how to program the demo board
and set the PiKey software up in the PSP.