DIYSEGAGameGear512KbFlashCartridge.

PleaseReadthroughthisentiredocumentbeforeyoucommencesoldering.
UsetheaccompanyingInstructionalVideosIhavemade,alongwiththisPDFDocumentforthebest chancesofsuccess.MyYouTubeChannellinkisshownbelow: http://www.youtube.com/user/NLEproGUY

Stillneedsomemorehelp?JointheGAMEBOYELECTRONICSGroup.
AgroupwhereHobbyists,Students,TechniciansandEngineers;cancollaborate ideasonbothHardwareandSoftwareforvariousHandheldgameconsoles.
ClickthelinkbelowtoJoin:

http://groups.yahoo.com/group/GAMEBOY_Electronics/
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SEGAGameGearD.I.Y.512KbFlashCartridge StepbyStepGuide By GerryOBrien Revision1.3 October2010 IMPORTANTNOTE:Electronicseducationandhandsonexperiencevariesfrom usertouser.BeadvisedthatthisStepbyStepguideistargetedtothose individualsthatmayneedalittlehelpalongtheway. TheprovidedPCBlayoutisasinglesideddesignandwasonlyintendedtobeused duringtheresearch&developmentstagesofthisproject.Itwasmerelya prototypedesign.WiththisinmindIdesignedtheboardwithboththetracelines andcomponentsononeside,whilehavingthewirebridgesontheother.Ialso intentionallymadethePCBlayoutmuchlarger.Allofthiswasputinplaceto maketroubleshootinglessofaburden.ObviouslyalargesizedPCBisadownfallif youplanonusingthisforregularGameplay.TheprototypePCBisalmostaslarge astheGameGearitself.Ifyouintendtoetchyourownboard,Ihighlyrecommend thatyouusetheprovidedschematicfileandcreateadoublesidedPCBlayoutof yourown. YoucandownloadmyEagleschematic&PrototypeLayoutatthelinkbelow:
http://www.digitalcircuitry.com/FILES/Electronics/SEGA/GameGear/SEGA_GameGear_Flash_Cart_Schematic_Pack.zip

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Introduction: Foralittleoverayearnow,IhavebeenworkingondevelopingaSEGAGameGearFlashCartridgefor theavidElectronicsHobbyist.Iamstillworkingoncompletingmy1Mbyte+version.However,forthe timebeingIhavecompletedacircuitdesignthatpermitsustointerfaceageneric512KbFlashchip. Myschematicdesignisshownbelow:

TheSchematicincorporatesaSEGA3155235Mapperchipanda4MbitFlashchip.Ihaveincludedmy PrototypePCBdesignaspartoftheEagleschematicdownload.MyPCBlayoutissinglesidedandwas merelydesignedasaprototype.WiththisinmindImadethePCBmuchlargertomaketroubleshooting lessofaburden.Thisisadownfallifyouplanonusingthislayoutdesignforregulargameuse.ThePCB isalmostaslargeastheGameGearitself. SeetheImageonthefollowingpage.

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 IwasnotgoingtoincludethePrototypePCBbutIfiguredsomeofyoumayenjoyetchingaboardof yourown.ThisboardwasdesignedwithtracelinesandcomponentsontheTopsideandwirebridges ontheBottom.Feelfreetomakeyourownmodificationstothelayout,oryoucanmakeyouown LayoutdesignbyusingtheprovidedSchematic.Someofyoumaywanttoattemptdesigningadouble sidedPCB.Thiswouldreducetheoverallsizeimmensely.Ifyouplanonetchingtheboardabove,make suretouse1/32thicknessboards.TheGamegearCartridgeslotwillonlyaccommodateaPCBofthis thicknesswhenusedwithastandardcartridgeenclosure.YoucanalsointerfacethisPCBtoaGG cartridgeviaa34wireRibboncable. YoucandownloadmyEagleSchematicandPrototypelayoutdesignatthelinkbelow:

http://www.digitalcircuitry.com/FILES/Electronics/SEGA/GameGear/SEGA_GameGear_Flash_Cart_Schematic_Pack.zip

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NowforthoseofyouwhodonothavetheequipmenttoetchyourownPCBs,Ihaveanalternative option.Now,thisoptionhasamajoradvantageovertheEtchyourownboardmethodshownabove. Theadvantageisthatyourfinalproductismuchsmallerinsize.Itinvolvessomesolderingwork,anda lotofpatience.Thenagain,mostofusdoingthesekindsofprojectswouldhavetohavealotofpatience otherwise,wewouldprobablygoinsane. So,basedonthefactthatmydesignusesanSMS3155235Mapperchipanda32pinmemorychip,we canuseaSegaMastersystemGameCartridgePCB.NowitdoesntmatterhowyouinterfacethePCBto theGameGear.Someofyoumaywishtomodifyvariousadaptersorinterfaceyourflashchipdirectly insidetheGameGear.Regardlesshowyouproceed,knowthatthemethodIhavelaidouthereis probablythebestwaytominimizetheoverallsizeofyourFlashcartridge.Aslongasyoumatchyour enddesignwithmyschematic,youllbegoodtogo. IhavetakenthelibertyofputtingtogetheraFullsetofproceduresforyoutofollow.Ihaveincorporated severalPhotographstoprovideasmuchdetailaspossibletohelpyoualongtheway. SobyfollowingthisPDFdocumentandwatchingmyYouTubeInstructionalvideosforthisproject,Im sureyouwillbevictoriousinbuildingyourveryown512KbSEGAGameGearFlashCartridge. Cheers!Andgoodlucktoyou. KindRegards, GerryOBrien

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PROCEDURES: STEP#1: ThefirststepistodesoldertheoriginalROMchipfroma4MbitSMSgameCartridgePCBandalso desoldertheIntegratedROM/MapperchipfromaGameGearCartridgePCB. AGameGearROMchipisactuallyaROM&Mapper/MemoryBankcontroller,integratedintoone. AscomparedtoanSMScartridge,thechipsareseparate.BasedonthefactthattheSMSandthe GameGearareessentiallythesamesystem,wecanuseSMSMapperchipswiththeGameGear. Mapperchipssuchasthe3155235modelarefoundinmost4MbitSMScartridges.TheSMS AFTERBURNERgamecartridgeisanexampleandisthecartridgerecommendedforthisproject. The3155235Mapperwillaccommodatea512KbFlashchipandisthemainreasonwhyIhaveselected itforthisproject.IalsorecommendusingTheATMEL4MbitFlashchipAT49F040. NotallofyourbackupROMimageswillrunusingthe3155235Mapperchip(Codemastersgames) butmostdo.ThisMapperchipshouldalsosufficewhenrunningyourowncustomcode.

Sonic2GameGearcartridgePCBAfterburnerSMSCartridgePCB(ROMbottomchip)

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ByusingtheAFTERBURNERcartridgePCB,yourfinalFlashCartwillbeonlyslightlylargerthana standardGameGearcartridge.

IfyouplanonrunningyourowncodeontheGG(GameGear)andyouwishtohaveRAMsupport,you canalsousetheSMScartridgePCBPHANTASYSTARwhichhasintegratedRAMandalsoabattery backup.Although,keepinmindthatyourFinalcartridgewillbelargerinsize. Now,ifyoudon'thaveaccesstoaSpecialDesolderingIron,thebestwaytoremovetheexistingsolder fromtheROMpinsistouseRosinFLUXsolutionandcopperWireSolderwick.Thisisavailableatalmost anyElectronicsComponentstoreorevenRadioShack. CoattheCopperWirewickwithRosinFluxsolution.Whenthiswickthencomesintocontactwith heatedmoltensolder,itwillchemicallybondthesoldertotheCopperWirewick.Justlikemetaltoa magnet,itwillattracttheSolderawayfromtheIC'sPINs. SomepeoplecallthisThewickingeffect.

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Oncethedesolderingiscomplete,yourcartridgePCBsshouldlooksimilartotheimagesbelow.

ThisPCBshownaboveisfromtheSonictheHedgehogGameGeargameCartridge.

ThePCBshownhereisfromtheAFTERBURNERSMSgameCartridgewiththe3155235Mapperchip. ThestandardfilterCapacitorsarenotshownintheimageabove.Thereareusuallytwo10nFceramic capacitorsandasingle47uF16Voltelectrolyticcapacitor(SeePage6).Replacetheelectrolyticcapacitor withanewreplacement.ThesecapacitorsservetoridanyvoltagespikesorNoisethatmayoccuron thedataoraddressbus.Thesespikescansometimescausetheloadedgametofreeze.Itisgood practicetohaveaFiltercapacitorconnectedbetweentheVccandGndofyourICspinsandinclose proximity. Page|8

Nowforshort,IrefertothecontactsonthegamecartridgePCBsasaTABandIwillrefertothese contactsassuchthroughoutthisPDFguide. SEGAGameGear(GG)CartridgePCBshownbelow:

SEGAMasterSystem(SMS)CartridgePCBShownbelow:

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STEP#2: NowwedonotusealloftheTABcontactsonthecartridges.YoucanpretintheSMScartridgeedge contacts(TABs)&theGameGearROMcontactswhichhaveallbeenhighlightedinREDorbyaRED squaretoshowsinglesolderpoints.SeetheImagesbelow. CertainTABcontactsontheSMScartridgePCBdonothaveanytracelinesconnectedtothematall. Thereforewecanomitsolderingtothese.PrecoatalloftheTABcontactsHighlightedinRED,withFlux andthenapplyenoughsoldertomakeafirmconnectionwiththe30AWGsizewirethatwewillbe solderingtoeachoftheseTABs.

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 Thereare33wireconnectionsintotalthatwillbegoingfromtheSMScartridgePCB,totheGameGear PCB.Youcanuse30AWGwireoraribboncableifyouwish.TheseconnectionsformtheInterface Busbetweenthetwocartridgeboards.MakesuretoPreTinoratleastapplyfluxtothestripedendsof your33sectionsofwirebeforesolderingtheinterfaceBustogether.Thisistimeconsumingbutworthit intheend.Performingthisstepwillresultinacleanandperfectsolderingconnectionasopposedto thosethatskipthisstep.Trustmeitsworthyourwhile. ThenextstepisontheGGcartridgePCB;makesuretocutthetracebridgebetweenthetwocontacts forTAB#41&42highlightedintheimageabove. Page|12

AlsodesolderthetwosurfacemountceramiccapacitorslabeledasC1&C2.Thesearenoisefilter capacitors.WealreadyhavenoisefiltercapacitorsinplaceontheSMScartridgePCB,sothesearenot requiredandshouldberemoved. ToStripthe30AWGwire,useawrap/striptoolsimilartothisoneshownbelowbyOKIndustries.You canfindtheseoneBayoratvariousElectronicscomponentstores.EBaysellstheseforabout$25.00 withfreeshippingwithinNorthAmerica.SeeeBayStorehttp://stores.ebay.com/Goodtronic

Makesureyour33sectionsofwireareabout3Inchesinlength. Step#3: NowwecanbeginsolderingthecartridgeinterfaceBus.Forthisstep,weneedtomatchuptheTAB contactnumbersbetweenthetwocartridgePCBsaccordingtotheCartridgeInterfaceBuswiring tableshownonthefollowingpage. Justtoclarify,inreferencetotheTABcontactsontheGameGearPCB,thereareonlytwoTABcontacts thatweactuallysolderto(TAB#26&39).ThereasonforthisisbecausetheseTABsdonothaveany tracelinesconnectedtothemandthereisnootherpointforustomakeasolderingconnectionto them.AlloftheGameGearTABsplugintotheGameGearcartridgeSlot,sowedontwanttoclutter themupwithtoomanywiresandsolder.WesoldermostofourinterfacewirestotheequivalentROM contactswhichconnecttotheTABsviaPCBtracelines. UsetheprovidedGameGearcartridgeTABcontacts&SolderingPointsdiagramontheprevious page.IhavelabeledtheROMcontactwiththeirequivalentTAB#numbers. Page|13

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OnceyouhavecompletedsolderingthePCBinterfaceBUStogether,yourPCBsshouldlooksimilarto theimagebelow.

YoullnoticeontheGGcartridgePCBontherighthandside,therearethreeextrawiresthathavebeen leftunconnected.Theseareforthetoggleswitchthatwilldistinguishwhetherornotyouarerunning theGameGearinSMSmodeorinGGMode. Thesethreeaddedwiresgiveyouatotalof36wiressolderedtoyourGGcartridgePCB. ThewireforGGTAB#42isconnectedtoeitherVccorGNDtodeterminethemodeofoperation.When TAB#42isconnectedtoGNDtheGameGearisinGGmode,andwhenconnectedtoVccitisinSMS mode.SoyoucanplaybothSMS&GGbackupROMswiththissetup. UseapermanentmarkerandplaceasinglehashmarkontheendofthewireforGGTAB#42.Then applytwohashmarksforVccandThreeforGND.Wewillneedtoidentifythesewireslaterwhenwe connecttheToggleswitch. Page|15

Step#4: Next,cutanopeningonthetopofaGGcartridgeenclosuretoallowtheinterfacewirestopassthrough. Iusedapairofcutterswhichdidnotcutverywell.IwouldsuggestusingaDremelToolorafinetooth saw.Usingapairofcuttersisnotascleanofacut.Asyoucanseeintheimagesbelow,theplasticcan crackanddoesnothaveasmoothedge.Sokeepthatinmindwhencuttingtheenclosure.

Step#5:

Thenextstepistoattacha32PinLeafsockettoaccommodateourZIFsocketwhichwewillbeusingfor attachingourflashchipafterprogramming.Theimagesbelowshowsastandard32pinleafsocket,and youllnoticetheindentationattheTopedge.ThisispresentforproperPinidentification.

Firstbendtheindicatedpinsontheleafsocketouttothesidesasshownintheimagesbelow. (ONLYBendPinNumbers1&31) Page|16

 BackSideshownbelow:

SolderaBluewiretoPIN#1&aREDwiretoPIN#31.PushtheLeafsocketontotheSMSPCBinplaceof theremovedROMchipasshownintheimageonthefollowingpage.Makesureitissnugandisplaced ascloseaspossibletothePCBsurface.

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 JustbesidePIN#31oftheleafsocket,thereisasmallholeintheSMSPCB.LoopbothRED&BLUEwires aroundandundertheleafsocket.Passbothwiresthroughtheholesothewirescomethroughtothe soldersideofthePCBasshownintheimagebelow.

Next,soldertheleafsocketinplaceandalsosoldertheRED&BLUEwiresconnectedtotheLeafSocket, totheSMSPCBROMPinholes#32and#31accordingly. REDwire=PCBROMPinhole#32Bluewire=PCBROMPinhole#31 Page|18

Step#6: Nowwemustplugthe32PINZIFintoourmodifiedleafsocket.Simplyplugitinbypressingdownfirmly. BesureyourLeafsockethasbeensolderedascloseaspossibletothePCB.Ifnot,youcoulddamagethe ROMPinholesonthePCBwhenyouareapplyingpressure.Seetheimagesbelow:

YoucanalsouseaPLCCtoDIPadapterifallyouhavearePLCC32packagechips. Page|19

STEP#7: ItisbesttotesttheFlashcartridgebeforewepermanentlyattachtheSMSPCBtotheGameGear Cartridgeenclosure.ToprogramourATMELAT49F040flashChip,wemustuseaUniversalProgrammer suchastheWillemUniversalProgrammershownbelow.YoucanpurchasetheWillemprogrammer oneBay.Thepricevariesbetween$30.00and$50.00Dollarsdependingontheseller.

ForStepsonProgrammingyourATMELFlashchiprefertomyaccompanyingYouTubeVideoattheLink below: http://www.youtube.com/user/NLEproGUY#p/u/0/TNukYjpRieM ThevideolinkaboveisVideoClipPart#5ofmyGameboyFlashcartinstructionalvideo.ThesameFlash chipisusedinbothoftheseflashcartprojects.(ATMELAT49F040) Page|20

STEP#8: OnceyourFlashchiphasbeensuccessfullyprogrammed,lockitintoyourFlashCartZIFsocket.Placethe SMSCartridgePCBovertopoftheGameGearCartridgeasshownintheimagebelow.Proceedtoplug theGGcartridgeintotheGameGearconsoleallowingtheSMSPCBtorestonthebacksideoftheGG enclosurewhiletesting.MakesureyoutemporarilyconnectGGTAB#42&41togetherwhiletestinga GameGearbackupROMimage.

Ifbychance,youturnontheGameGearandallyougetisaBlankscreen,tryflashingyourchipwitha differentROMimage.Remember,notallbackupROMsworkwiththe3155235Mapperchip.Ifyoustill haveproblemsgettingyourdatatoload,chancesarethereisashortsomewherealongtheInterface Busorpossiblyanintermittentsolderingconnection.Inthiscase,Iwouldsuggestusingacontinuity testerorMultiMeterandcheckingeachwireontheinterfaceBustoconfirmtherearenoshorts present.AlsoverifythatyourGGCartridgeTABcontactsarefreeofanydriedFluxsolution.Thismay preventasolidconnectionbetweentheTABcontacts,andtheGGCartridgeSlotcontacts.Useacontact cleanersolution,FluxremoverorIsopropylAlcoholtocleanyourTABcontactsifneedbe. Page|21

YoucanalsotryremovingandreinsertingtheGGCartridgetwoorthreetimes.Youwillknowthatthe ROMDatahasbeensuccessfullyloadedtotheGameGearwhenthescreendisplaysthetext PRODUCEDBYORUNDERLICENSEFROMSEGAENTERPRISESLTD..Thistextisthenfollowedbya SEGALogographicasshownintheImagebelow: Firstdisplay:

Seconddisplay:

TheSEGAlogomayvarydependingonthebackupROMbeingloaded.Oncethesescreensappear,thisis asuresignofVICTORY!YourCartridgeisnowworking.AllthatremainsistosecuretheSMSPCBtothe backoftheGGcartridgeenclosureandconnectyourToggleswitchtotheappropriatewires.Someof youmaywishtoattachtheSMSPCBtotheBacksideofyourGameGearpermanently.Regardless,Iwill showyouhowIattachedtheSMSPCBtoastandardGGcartridgeenclosure. Page|22

STEP#9: GluetwostripsofrubberpaddingtothetopsectionofaGameGearCartridgeenclosure.Usinganold MousePadissufficientforthisstep.ThegapbetweenthetwoRubberstripswillprovideroomforthe Interfacewirestopassthrough.Seetheimagebelow:

Irecommendusingastandardwhitegluegunforattachingtherubberpieces.NOTE:Youcouldalsocut theRubberintoaUshapewhichwouldthencovertheentiresoldersideoftheSMSPCB. Oncethegluehascooled,youcanencasetheGGPCBintoitsEnclosure.LaytheGGcartridgeandSMS PCBdownonthetablewiththeircomponentssidefacingup.TaketheSMSPCBliftitupandplaceiton topofthetwostripsofRubberallowingtheInterfacewirestopassbetweenthem.TheInterfacebusis nowunderneaththeSMSPCBasshownintheimagesbelow.

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YoucanuseasmallamountofwhitegluetoholdtheSMSPCBinplace,justmakesureyoudontglue anyoftheinterfacewires.Thiswouldbeadisasterifyoueverneededtofixashort.

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STEP#10: ThenextstepistosoldertheToggleswitchtothethreeunconnectedwirescomingfromtheGG cartridgePCB.Solderthewireyoumarkedearlierwiththemarker(GGTAB#42)tothecenterpoleof yourthreepoleToggleswitch.NextconnectVcc&Gndtothetopandbottompolesasshowninthe imagebelow:

YoucanalsouseJumperpinsasanalternativetotheToggleSwitch.

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STEP#11: ThelaststepistosimplyattachthetoggleswitchtoyourCartridgeandthenprintoffaDecalgraphicfor yourGGEnclosure.Anexampleimageshownbelow:

Sothatsitfolks!IwishyouallthebestinbuildingyourownSEGAGameGearFlashCartridges.

KindRegards GerryOBrien Page|26