Freeze the Dizz Jameco Part No

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1 Freeze the Dizz Jameco Part No This project is based on a children s arcade game. Twenty LEDs are placed on a ring and each takes turn to light up forming a rotating light spot. If a push-button switch is pressed, the light spot freezes. If the light spot happens to land on the winning position, a buzzer is triggered. The rotating speed is adjustable by a speed dial. See a video demonstration here: You can learn basic building blocks of electronics circuit such as flip-flop (CD4013), counter (CD 4017), one-shot and 555 oscillator with this project. You can see how they are put together to achieve the circuit operations desired. You will test each individual parts of the circuit to understand the roles of each IC and major components. Experience Level: Intermediate Time Required: Hours

2 Kit Overview Circuit Schematics Circuit Operation The circuit consists of the following major blocks: buzzer oscillator (U2B), clock oscillator (U2A), two count-by-ten counters (U4, U5), alternating LED bank switches (Q1, Q2, U3B), one-shot circuit (U3A) and LED drivers U6, U7, U8). U2A (LM556 dual timers) is a 555 equivalent timer configured in the astable mode. The frequency is adjusted by VR1.The output clock signal at U3 pin 5 is fed to pin 14 of U4 and U5 to run the CD4017 Decade Counters. Each counter s output bus Q0 through Q9 drives a bank of ten LEDs making them light up in sequence. The two counters U4 and U5 operate in parallel. To form a single light spot with LED0 LED19, one of the two banks of LEDs will be suppressed. This is done by Q1 and Q2 each controlling a bank and only one is allowed to turn on. Q1 and Q2 are controlled by U3B (CD4013 Dual

3 Flip-Flop). The Q-bar (pin 12) of U3B is connected to the Data input (pin 9) forming a toggle flip-flop. When counter U4 completes one cycle of counting, a positive edge at Cout (U4 pin 12) causes U3B outputs (pin 12 and 13) to toggle, switching the two LED banks alternatively. The outputs of counters U4 and U5 are delivered to U6, U7, and U8 (ULN2003 Darlington Array) to drive the 20 LEDs. The positioning of the LEDs is important. LED9 of U4 Q9 should be next to LED10 of U5 Q0 so that the light spot will run in sequence. Each bank of LED takes one half of the ring driven by Q0 through Q9 of the counters. In this configuration, you will notice that (for example) LED11 corresponding to U4 Q1 will be directly opposite to LED1 of U5 Q1. Even though the two counters are running in parallel, they may not count in sync as the initial count during power up is uncontrollable. This is solved by sending the Cout pulse of U5 at pin 12, through C6 and R16 (to shorten the pulse width) to reset U4 pin 15 so that they will count in sync after the first reset pulse has arrived. U3A is configured as a one-shot circuit. When SW1 is pressed, the Q output of U3A flips to the high state. Through the delay action of R2 and C3, the flip-flop is cleared by pin 4 after about 2 seconds. The one-shot pulse triggered by SW1 is delivered to U2A pin 4 to stop the clock oscillator and the counting action of U4 and U5. The pulse also lights up LED20 through U6 pin 7. Counting resumes when the pulse ends. U2B is another 555 equivalent oscillator driving a piezo buzzer. Q3 acts as a logic decision gate. To trigger a winning buzz, three criteria need to be established through R8, R9 and R11. R8 signals that the one-shot circuit is triggered (SW1 pressed), R9 signals that the winning bank of LED is activated and R11 signals that the winning LED is lit. Any other state will turn on Q3 and send a low signal to U3B pin 10 to suppress the buzzer. The buzzer sound pitch is adjustable by trimmer resistor VR2. The power is supplied by a wall power adapter that can provide 8-12V DC or AC. Diode D1 protects the system against wrong power polarity and also serves as a rectifier for AC power input. DC battery power of the same rating is also acceptable. The LM78L05 voltage regulator provides +5V power supply to drive the electronics and LEDs. The current consumption is very low with each LED consuming ~5mA and ~10mA for the buzzer. The total current consumption should not exceed 30mA at any given time.

4 Required tools or supplies not included Enclosure box Low voltage signal wires Wall power adapter, DC or AC 8 12V, 100mA (ex. Jameco part number ) Adhesive and fastener to secure components and circuit board Soldering equipment Digital Multimeter Drill and hardware for enclosure box carpentry Oscilloscope preferred. Est. Time Required to Complete: hours

5 Bill of material Component Quantity Jameco Part Number Manufacturer Part Number 1 PIEZO BUZZER SW1, Switch Push Button OFF (ON) Connector Power Male 3 Position PROTOTYPE BUILDER,4.5 INCH x3.3 INCH,PCB U1, Standard Regulator 5V, 100mA L05 6 D1, DIODE, 400V, 1A N VR1, POTENTIOMETER,1M,RV24AF-10-15R1- B1M,LINEAR TAPER, 1/2 WATT,.335 INCH KNOB,1/4 INCH SHAFT,27.1MM,JK- 901C,BLACK/ALUMINUM,WITH SET SCREW VR2, POTENTIOMETER,100K OHM,3362P- 104LF,SINGLE TURN,.5 WATT,CERMET U2, IC,LM556N,DUAL TIMER,DIP LM556CN 11 U3, IC, CD4013, DIP CD U4, U5, IC, CD4017, DIP CD U6, U7, U8, Transistor Darlington NPN 50V 0.5A 16-Pin PDIP ULN2003A 14 U2, U3 SOCKET, IC,14PIN U4 - U8 SOCKET, IC,16PIN Q1, Q2, TRANSISTOR,2N3906,PNP,GP N Q3, TRANSISTOR,2N3904,NPN,GP N LED0 - LED19, LED, Uni-Color Green LED20, LED, Uni-Color Red C1, C2 CAP,RADIAL,100uF,50V,20%,85C C3, CAPACITOR,RADIAL,1UF,25V, 20%,85C C4, CAP,MONO,.22uF,50V,20% C5, C8, CAP,MONO,.1uF,50V,20% C6, CAP,MONO,.001uF,50V,20% C7, CAPACITOR,CERAMIC,DISC,.0022UF C9, CAP,RADIAL,4.7uF,50V,20%,85C R1, R12, R14, R15, RESISTOR,CARBON FILM,47K OHM,1/4 WATT,5%, R2, RESISTOR,CARBON FILM,2M OHM,1/4 WATT,5% R3, R4, R13, R16, RESISTOR,CARBON FILM,10K OHM,1/4 WATT,5% R5 - R7,.RESISTOR,CARBON FILM,680 OHM,1/4 WATT,5% R8 - R11, RESISTOR,CARBON FILM,470K OHM,1/4 WATT,5%

6 Component pin identification Component Pin Identification Schematic representation U1, 78L05,Voltage Regulator D1, 1N4004, Diode U2, LM556, IC, Dual Timer U3, CD4013, IC, Dual D -Type Flip-Flip

7 U4, U5, IC, CD4017, Decade Counter U6, U7, U8, IC, ULN2003, Darlington Array Q1, Q2, 2N3906, PNP Transistor Q3, 2N3904,NPN Transistor

8 LED0 - LED19, Green LED LED20, Red LED C1, C2, C3, C9, Electrolytic Capacitor C4 C8, Capacitor

9 R1 R15, Resistor, 0.25W SW1, Push Button Switch Power Jack (center positive) VR1, POTENTIOMETER VR2, Trimmer Resistor PIEZO BUZZER

10 Resistor color codes (5% error tolerance) Name Value Resistor color code R1, R12, R14, R15 47K Yellow-Purple-Orange-Gold R2 2M Red-Black-Green-Gold R3, R4, R13, R16 10K Brown-Black-Orange-Gold R5, R6, R7 680 Blue-Grey-Brown-Gold R8, R9, R10, R11 470K Yellow-Purple-Yellow-Gold

11 Project Steps Step 1: Enclosure box planning and construction Objective: Enclosure box with components installed A cookie gift box made from cellulose or plastic material is ideal for this project. It should be about the size of a 12" pizza box. Plan the locations of the LED ring (LED0 LED19), SW1, LED20, VR1, power jack and the buzzer. Drill holes and attach components. The winning location shown on the circuit schematic is LED13 connected to U6 pin 7. With the LED ring installed, solder the anode (longer leads) of LED0 LED9 together forming the first bank to be connected to R6. Do the same for the second bank LED10 LED19 to be connected to R7. You might want to spray-paint the box before installing the components. The circuit board can be screwed into two strips of soft wood that are glued to the box interior.

12 Step 2: Component placement on circuit board Objective: Place circuit board components This is a component planning step without soldering. Insert all components on the circuit board without soldering. Pay attentions to the signal flow of the circuit. The recommended placement is to arrange the ICs in 3 rows. U6, U7, U8 are on the top row, with their outputs (pin 10-16) close to the top edge of the board where some 20 wires will go to the LED ring. Place U4, U5 (CD4017) on the center row with pin 1 facing U6, U7, U8 (ULN2003). U2 (LM556) and U3 (CD4013) are placed at the bottom row with transistors, resistor and capacitors near them. Run wires from the circuit board to the power jack, VR1, SW1, buzzer, LED0 LED19. Try to arrange the components so that these external wires access the circuit board near the sides. Some components may have a different size than the placement plan given below and therefore may not be possible to have identical placement. It is important to place all components before soldering to avoid time-consuming rework after soldering. Use Scotch Tape to secure IC sockets and components to the circuit board if necessary.

13 Step 3: Circuit board wiring Objective: Solder circuit board components and wires Solder the components on the circuit board according to the wiring diagram below. It is recommended to start with the top side signal wiring, then bottom side signals followed by top side power ground and bottom side power ground wires. Pin 9 of U6, U7 and U8 are unconnected. Pay attention to the pin configuration and polarity of Q1, Q2, Q3, U1, D1, C1, C2, C3, and C9. Note that the components are mirrored left/right when viewed from the bottom side.

14 Use the wiring plan as the reference. Do not use the prototype photos. The kit might contain slightly different components.

15 Step 4: External component wiring Objective: Solder all components and wires This step completes all internal and external wiring of the circuit. The wiring diagram is shown below. It is a good practice to label the external wires because you may need to unconnected and re-connect some wires to locate problems. Wrong wiring may cause damages to electronic components. Use the continuity test of DMM to check wiring.

16

17 Step 5: Project completion and testing Objective: Final circuit testing and IC installation There are many components and wirings in this project. Wiring errors may cause the circuit behave in unexpected ways. Severe errors like shorting an IC pin to power or ground may cause permanent damage to the component. The Circuit Testing procedure outlined below is designed to detect errors and avoid costly mistakes. Be sure to follow the test procedures in the order described.

18 Circuit Testing All electrical construction and wiring should be completed before conducting circuit testing. Completion of mechanical construction is not necessary. Make sure that you follow the test procedures below in the order described. This is essential to ensure that you have wired the components properly. It also minimizes the risk of permanently destroying any IC due to improper construction or soldering. When installing ICs to their sockets, pay attention to the polarity. Wrong installation may cause permanent damage to the ICs. Follow the test procedures in the order described Test 1A: GND network continuity The purpose of Tests 1A, 1B and 1C is to make sure that the soldering work of the power supply network is good. This is done without installing any ICs on the sockets. Do not insert U2 through U8. Do not apply any power to the circuit. Set your Digital Multimeter (DMM) to beeping continuity test or resistance measurement. Pick a ground signal, for example the negative pin of C1. Measure the continuity to every test-point listed below to ensure that the resistance is less than a few Ohms. Refer to Figure 1 for ICs and pin locations. Test 1A: Test-points for GND network continuity test. No power should be applied. U1 GND pin U2 pin 7 U3 pins 3, 5, 7, 8, 10 U4 pins 8, 13 U5 pins 8, 13,15 U6 pin 8 U7 pin 8 U8 pin 8 R1, C1, C2, C3, C4, C5, C7, C8 Power Jack Piezo Buzzer

19 Figure 1. ICs and pin locations for Tests 1A, 1B, 1C and 1D. Test 1B: +5V network continuity This is the same as Test 1A but repeated for the +5V network. The following test points should be connected: Test 1B: Test-points for +5V network continuity test. No power should be applied. U1 VO pin U2 pin 14 U3 pin 14 U4 pin 16 U5 pin 16 Q1, Q2 pin E R5, R10, R12, R13, R15 SW1

20 Test 1C: IC output short-circuit This is an important test ensure that no output pin of any IC is shorted to the power or the ground network. This condition often causes large current to flow through the ICs leading to permanent damages. Do not insert U2 through U8. Do not apply any power to the circuit during this test. Set your DMM to beeping continuity test or resistance measurement. Measure the resistance of an output pin at an IC socket to the ground. The resistance should not be near zero. Otherwise you have a short circuit at the pin. Repeat the same test from the IC outputs to the +5V power network. Test 1C: Test-points for IC output pins. No power should be applied. No pin should be shorted to power (+5V) or ground. U2 pins 5, 9 U3 pins 1, 2, 12, 13 U4, U5 pins 1, 2, 3, 4, 5, 6, 7, 9, 10, 11, 12 U6, U7, U8 pins 10, 11, 12, 13, 14, 15, 16 Test 1D: IC sockets power supply In this test, we want to make sure that power is properly reaching all IC sockets and there is no short-circuit of the power supply network. Do not start this test if Tests 1A, 1B or 1C have not passed. Disconnect power from the power jack. Do not install any ICs U2 through U8. Use a DMM to measure the resistance between pin 14 and pin 7 of U2. It should be about 4K Ohms. This is from the internal resistance of U1 (78L05). If this resistance is only several Ohms, you have a power-ground short. Check your soldering work to locate the problem. Do not power up the circuit when there is a power-ground short. If all power network tests have passed, apply battery power 8 12VDC to the power jack. Measure the voltage across the following pairs of power supply pins of the IC sockets. The voltage should be 5.0V +/- 5%. Figure 2 shows the test setup. U6, U7 and U8 do not have +5V power supply. Measure the current consumption. It should be less than 5mA. Do not install any IC into socket until Tests 1A, 1B, 1C and 1D all passed. Doing so may cause IC damages. Check your soldering work.

21 Test 1D: Power supply of IC sockets +5v GND U2 pin 14 U3 pin 14 U4 pin 16 U5 pin 16 U2 pin 7 U3 pin 7 U4 pin 8 U5 pin 8 Figure 2. Measuring power supply of IC sockets in Test 1D. Test 2A: Buzzer oscillator With Tests 1A, 1B, 1C and 1D, you have verified that the proper power supply has been delivered to the IC sockets and there are no severe abnormal conditions of the power supply. You are ready to energize the ICs. Tests 2A and 2B verify the two oscillators of LM556.

22 Disconnect the power supply and insert U2 (LM556). Do not insert U3 through U8. Use a bypass lead to connect between pin 7 (GND) and pin 12 (Q-bar) of U3 socket. A scrap pin lead from a resistor or capacitor is ideal for this purpose. Use another bypass lead to connect between pin 8 and pin 13 of U8 socket. This will turn on the buzzer oscillator. The setup is shown in Figure 3. Figure 3. Use two bypass leads to turn on the buzzer oscillator in Test 2A. Now apply battery power to the power jack, you should be able to hear the buzz tone. Adjust VR2 to change the buzz tone and sound volume to the desired level. A piezo buzzer has resonance frequency ranges depending on its physical construction. You will notice that certain frequencies near resonance produce louder sound output. If the oscillator is not working, check VR2, R13, R14, C7, C8 and Q3. Also check the voltage at pin 10 of U2. It should be near 5.0V for the buzzer oscillator to work. If it is less than 3.0V, check the bypass leads, Q3, R8, R9, R10, R11 and R12. Test 2B: Counter oscillator In this test, we want to verify that the oscillator of U2A (LM556) is working. Disconnect the power and install a bypass lead between pin 2 and pin 14 of U3 socket. Do not install U3 through U8. The test setup is shown in Figure 4.

23 Check the waveform at pin 14 of the U4 socket with an oscilloscope. You should see a square wave with 5Vp-p. Adjust VR1 to make sure that the oscillator frequency can change between 3 to 150Hz. Check VR1, R15, C4 and C5 if the oscillator is not working. Also check the voltage at U2 pin 4. It should be near 5.0V for the oscillator to work. If it is less than 3.0V, check the bypass lead on U3 socket. Check pin 14 of U5 socket. You should get identical signal since the two pins are connected together. Figure 4. Oscilloscope waveform of counter clock in Test 2B. Test 2B without oscilloscope Without an oscilloscope, you can measure the DC level of the clock signal. This can give you some indication of the oscillator output although it is not as reliable as an oscilloscope. Disconnect the power and install a bypass lead between pin 2 and pin 14 of U3 socket. Do not install U3 through U8. Use the test setup shown in Figure 4.

24 Dial VR1 to about half turn position and apply power. Measure the voltage at pin 14 of U4 socket. It should be about 2.5V. If you reduce the resistance of VR1, the oscillator should run at a higher frequency and higher duty cycle. This will increase the voltage reading. If the voltage reading is constantly at a certain voltage and does not change with VR1, the oscillator is not working. Check VR1, R15, C4 and C5 if the oscillator is not working. Also check the voltage at U2 pin 4. It should be near 5.0V for the oscillator to work. If it is less than 3.0V, check the bypass lead. You should get identical reading at pin 14 of U5 socket since the two pins are connected together. Test 3: CD4017 counters In this test, we want to verify the operations of the CD4017 counters U4 and U5. Disconnect power supply and insert U4 and U5. Do not install U3, U6, U7 and U8. Install a bypass lead between pin 2 and pin 14 of U3 socket. Apply power and observe the waveforms at pin 14 and pin 1 of U4 with a two-channel oscilloscope. You should see a 5Vp-p pulse at pin 1 for every ten clock cycles of pin 14, as shown in Figure 5. Repeat the measurement for the following signals of the counter pins: 1, 2, 3, 4, 5, 6, 7, 9, 10, and 11. Pin 12 of U4 is the Carry Out pin. It is at logic high for the first half of the courting cycle and goes to low at the second half. The test setup and the observed waveform are shown in Figure 5. If the counter is not working, check if pin 14 is receiving the proper clock signal. Also check that pin 13 and pin 15 is near 0V to enable the counter. Repeat the same test for the corresponding signal pins of U5.

25 Figure 5. Counter outputs and Carry Out signals. The sync pulse at pin 15 U4 occurs when the Carry Out (pin 12) of U5 goes from low to high. At that time, C6 and R16 generate a positive pulse of about 1us to reset U4 to zero count so that U4 and U5 will synchronize their counting. The pulse occurs once every ten clock cycles. The waveform is shown in Figure 6.The pulse is very narrow (about 1us) compared to the clock cycle (about 10ms). Use the highest clock frequency by dialing VR1 to the lowest resistance.

26 Figure 6. Counter sync pulse at U4 pin 15. Test 3 without oscilloscope Disconnect power supply and insert U4 and U5, CD4017. Do not install U3, U6, U7 and U8. Install a bypass lead between pin 2 and pin 14 U3 socket. The test setup is shown in Figure 5. Dial VR1 to the highest resistance for the lowest counting speed. Apply power and measure the voltage at pin 1 of U4. Since the positive pulse only appears once every ten clock cycle, the DMM will read near zero voltage when there is no pulse and near 5V when there is a pulse. However, many DMM voltage reading cannot response fast enough to a short pulse and the voltage reading may not go up to 5V. If you see a rhythmic rise and fall of the voltage reading with the low voltage near zero, the counter is probably working. If you dial VR1 to the fastest counting speed, the voltage value

27 should stabilize at 0.5VDC. If the voltage value is jumping and difficult to read, you can put a large capacitor (for example, 1uF) across the two DMM probes to try to get a sable reading. Repeat the measurement for the following signals of the counter pins: 1, 2, 3, 4, 5, 6, 7, 9, 10, and 11. For pin 12 (Carry Out) of U4, the voltage reading should be about 2.5V. If the counter is not working, check that U4 pin 14 is not constantly stuck at 0V or 5V. Also check that pin 13 and pin 15 are near 0V to enable the counter. Repeat the same test for the corresponding signal pins of U5. The sync pulse at U4 pin 15 is too short and cannot be checked with a DMM. The DC voltage level is near zero when measured with a DMM. Test 4: Counters and LED drivers ULN2003 This test checks that the counting pulses at U4 and U5 are driving LED0 LED19 properly. Disconnect power supply and insert U6, U7, and U8 (ULN2003). U3 is the only IC not installed in this test. Three bypass leads will be needed on the U3 socket between pin pairs (2, 14), (5, 13) and (8, 12). The bypass (2, 14) turns on the counter oscillator. The other two bypasses turn on both Q1 and Q2 so that the light spot of both counters are visible simultaneously. The test setup is shown in Figure 7.

28 Figure 7. Testing counters and LED drivers in Test 4. Apply power and you should see two LED light spots running in sequence, one from each counter. Check the counting sequence of the LEDs to make sure that you have soldered the wiring properly. Vary VR1 to adjust counting speed. Test 5: Complete system test Disconnect power supply and install U3. You should now have all ICs installed. Apply power and you should see only one LED light spot with each bank of LED taking turns to turn on. This gives the illusion of only one rotating light spot on LED0 LED19 even though the two counters are working simultaneously. If you still see two light spots, check Q1, Q2, R3 and R4. If you press SW1, the light spot should stop for about 2 seconds and then resume running. If counting is not stopped, check SW1, R1, R2 and C3. LED20 should be lit when the counting is momentarily stopped. If not, check R5 and the signal path from U3 pin 1 to U6 pin 10. If the light spot stopped but resume counting too quickly, you might have the polarity of C3 reversed or wrong value of R2. Dial VR1 to the lowest speed. Verify that if the light spot lands on the wining position, it will trigger the buzzer. Verify that all other positions will not trigger the buzzer.

29 If you concluded this test, you have completed the electronic construction of the project. Figure 8. All wiring completed and ICs installed.

30 Summary of test procedures Test procedures 1A: Continuity test of GND network. No power supply. Test setup Fig. 1 Test points U1 GND pin U2 pin 7 U3 pins 3, 5, 7, 8, 10 U4 pins 8, 13 U5 pins 8, 13,15 U6 pin 8 U7 pin 8 U8 pin 8 R1, C1, C2, C3, C4, C5, C7, C8 Power Jack Piezo Buzzer Passing criteria All test-points should be connected and have near zero resistance. 1B: Continuity test of +5V network. No power supply. Fig. 1 U1 VO pin U2 pin 14 U3 pin 14 U4 pin 16 U5 pin 16 Q1, Q2 pin E R5, R10, R12, R13, R15 SW1 All test-points should be connected and have near zero resistance. Test 1C: IC output pins shorted to power or ground. No power supply. Test 1D: IC socket power supply. Fig. 1 U2 pins 5, 9 U3 pins 1, 2, 12, 13 U4, U5 pins 1, 2, 3, 4, 5, 6, 7, 9, 10, 11, 12 U6, U7, U8 pins 10, 11, 12, 13, 14, 15, 16 Fig. 2 U2 (pin 7, pin 14) U3 (pin 7, pin 14) U4 (pin 8, pin 16) U5 (pin 8, pin 16) All test-points should not have near zero resistance to GND. All test-points should not have near zero resistance to +5V. No power-ground short circuit. 5.0V for all ICs power supply pin pairs. Test 2A: Buzzer oscillator U2B LM556. Fig. 3 N/A VR2 can adjust buzzer tone. Test 2B: Clock oscillator U2A LM556. Fig. 4 U4 pin 14 U5 pin 14 5Vp-p square wave at test points, adjustable by VR1.

31 Test 2B without oscilloscope. Test 3: CD4017 counters U4, U5. Test 3 without oscilloscope. Fig. 4 U4 pin 14 U5 pin 14 Fig. 5, 6 U4 pins 1, 2, 3, 4, 5, 6, 7, 9, 10, 11, 12, 15. U5 pins 1, 2, 3, 4, 5, 6, 7, 9, 10, 11, 12. Fig. 5 U4 pins 1, 2, 3, 4, 5, 6, 7, 9, 10, 11, 12. U5 pins 1, 2, 3, 4, 5, 6, 7, 9, 10, 11, VDC at test points, increasing voltage with higher frequency (smaller resistance at VR1). No 0V or 5V constant voltage at test points. Positive pulse for every 10 clock cycles at Q0 Q9 output pins of U4 and U5. Logic high for first 5 counts at Carry Out (pin 12) of U4 and U5. Logic low for the remaining counts. 1us pulse at U4 Reset (pin 15). 0.5VDC at each Q0 Q9 output pins. 2.5V DC at Carry Out pins. Test 4: Counters and LED drivers ULN2003. Fig. 7 N/A Two LED light spots, one for LED0 LED9, another one for LED10 LED19. VR1 can adjust LED light spot speed. Test 5: Complete system test. N/A N/A Only one LED light spot. SW1 can stop the light spot and resume. Winning position can trigger buzzer. Non-winning positions cannot trigger buzzer.

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