Got the KL25Z set up, until I got to the plunger sensor. The sensor window in the Pinscape setup, during the calibration process, and after, is spastic. Not a nice smooth black and white bar. When "contrast" added, looks like a spastic bar code. And the rest/max are jumpy as well.
1. I have checked continuity on the ribbon cable between all pins. That's good. I've checked all the solder points and reflowed a couple of them.
2. I have the small PCB aligned properly with the CCD.
3. I have the red ribbon cable side to Pin1 arrow on small PCB and Pin1 Arrow on main board.
4. I don't know if I have the light source correct yet but can't imagine that the light source is the issue since I've tried different light sources.
5. I haven't hooked up any buttons yet. Just the plunger and two USB cables.
6. I haven't fully tested the main board, just the KL25Z, so maybe something on the main board (?)
The first thing I'd do is try a strong light and see if you can get any response out of it. A couple of people have had similar problems that turned out to be a simple matter of not enough light. Try something like a desk lamp a foot or two away from the sensor pointing right at it. See if there's any difference between the light on and off, and try covering portions of the sensor to see if you get any reaction in different areas.
It it's still not working, the next thing I'd to is double-check that the connector board orientation is right. Here's a diagram of how they should line up. The sensor in this view has the glass window facing up, and the connector board has the silkscreened text facing up.

(The intended way to install it is to flip the sensor over from this view and install the connector board on its back, so that the board sits squarely over the sensor rather than sticking out to the side like this. But you can also install it sticking out the side like this if you prefer - they're equivalent electrically since the pins on the front and back of the sensor are the same. Flipping it over just minimizes the combined footprint to make it easier to install in a confined area.)
If the orientation looks good, I'd trace the continuity all the way from the KL25Z pads to the sensor pads, since there are several solder points and connectors in between. You can find a full pin diagram of the KL25Z here:
http://mjrnet.org/pi...sid=kl25zPinOut
What I'd do is open up the config tool and write down the three pin assignments you have for the sensor, then disconnect everything from USB and do the continuity checks to each of those KL25Z pin pads. Touch one probe to the KL25Z pad for one of the pins and touch the other probe to the TSL1410R pad for the corresponding pin, and make sure it goes all the way through. I'd use the pads on the opposite side of the sensor from the one where you soldered the connector board to make sure you're actually touching the sensor pin and not the solder.
Next, check continuity between the following pins on the TSL1410R directly:
SI1 = HOLD1 = HOLD2
CLK1 = CLK2
AO1 = AO2
SO1 = SI2
Vpp = GND
Next, plug the board into USB and power it up. Switch your meter to DC Voltage mode. Measure the voltage from red probe = Vdd to black probe = Vpp - both the pins pads on the TSL1410R again - and verify that you read +3.3V.
Edit: Dawned on me that I haven't hooked up power to the main board, so if I'm reading the schematic correctly, which is always in doubt, the sensor isn't getting the 5V it needs?
The sensor actually gets power directly from the KL25Z's 3.3V regulator, so I'm afraid that's not the problem.
Edited by mjr, 07 August 2017 - 09:59 PM.