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Assembly Manual IV-12 VFD-Uhr Jenny
Page 1 of 8
Assembly Manual IV-12 VFD-Clock Jenny Congratulations on your purchase of this stunning IV-12 VFD clock kit. In order to ensure a successful assembly, please read the following helpful hints.
Take it easy. Assembling the kit in a hurry often leads to frustration and mistakes. Troubleshooting your mistakes will take three times as long as taking it slow and doing it right.
You should work in a clear, well-lit area – daylight is preferred. Electronic tools, such as pliers, small side-cutters or tweezers should be handy. To assemble the enclosure you need a T8 (Torx) or SW2 Allen screwdriver. You will need a good soldering iron or a rework station with a 1 mm bit and a
maximum of 1 mm fine electronic solder. (This is most certainly not a plumbing job!)
You will need a multimeter with at least a 50 VDC range to test this device. It may be helpful to have a magnifying glass or a loupe to read the markings on the
components. Please assemble the board in the order stated below. This method has been
proven to minimize mistakes.
Additionally, this document includes:
The complete bill of material
The schematic of the clock
A very useful colored landscape hard copy of the parts placement. You should keep this diagram nearby when assembling the clock. The position of all resistors, capacitors and the most of the semiconductors are shown in different color footprints. If you are fitting many components, e.g. the bulk of 590 ohms resistors, first have a look at the diagram. All of the components are color coded. For example, all of the 590 ohm resistors are shown in green. Therefore, you only need to look for the green resistor footprints in the hardcopy and you can quickly place them on the PCB in the correct position without need to search for “that damn R20!”. This method provides a tremendous time saving advantage!
A printed operations manual for your VFD clock. Always keep this manual handy. Safety precautions: During assembly, operation, measurement, and maintenance extra precautions must be taken. This device generates high voltage and is potentially harmful. You should assemble the circuit at your own risk. The functionality cannot be guaranteed as assembling this clock requires skill and experience. By constructing this kit, you are verifying that you have the knowledge and skill required to properly and safely assemble this device. NixieKits.eu, its employees, its management and its affiliates hereby disclaim all responsibility for any claims, damages, or other liability incurred during the assembly, the construction, or the use of this device. The user is responsible for following all local and federal laws regarding the manufacturing of electronic equipment, environmental safety, and any other laws or statues that may apply. The clock should only be operated in a fully sealed enclosure.
Assembly Manual IV-12 VFD-Uhr Jenny
Page 2 of 8
The person who completes a kit and assembles this board and places it in an enclosure for operation is considered, by the German directive VDE 0869, to be a manufacturer and is compelled to provide his name and address in all documents when selling the clock or transferring ownership. Ready-to-use devices that are assembled from kits are classified as safety-related as an industrial made product. Okay, and now, Ladies and Gentlemen, start your soldering irons…
To begin, start first with all of the low profile components, such as the resistors and diodes. Do not yet install R6 and D8 because they will make installing and soldering the electrolytic capacitors
more difficult. Please take note of the position of the white dot printed on the board and the marker on the 2 long resistor packages (shown above). It is possible to install the package backwards but this will result in damage to the device. Also, please be aware of the (not-yet-installed) D8. It does not differ visually except for the printed label 1N5819.
Next, fit the MC34063A's (2), the TD62783AP's (2) and the 4511 integrated circuits. Again, be sure to install the components with the correct orientation. All of the ICs will be fitted without sockets. For extra heat dissipation please solder the MC34063A's from both the top and bottom of the PCB. After that is done, please solder both sockets for IC5 and IC6 but do not yet fit the PIC processors or the eight RGB LED's (your board may have come with the some or all of the LED's presoldered - don't worry). Solder crystal Q1 and
LED9 now. Please note for the correct orientation of the LED. Now it is time to fit all of the ceramic capacitors. C21 and C26 are fitted next to one of the TD62783AP's and have 100V capacity. Be careful not to mismatch the 100nF capacitors. There should be one unused 100nF 50V capacitor left – please keep them on a safe place for later use. Now solder the voltage regulator 78L05 and the four transistors BC337. The leads of these transistors are pre-cut so the parts will fall out when the PCB is turned upside down. To solder these components, first solder one pad from the top side and then invert the PCB. Next, you will solder the higher profile components such as the electrolytic capacitors, R2, the buzzer, the DC-jack and the inductors. Please use the photo to the right as a reference for the correct orientation of both inductors. This positioning will mitigate noise during operation. If you want, you may also secure the outer coils by adding a little bit transparent nail lacquer.
To install the electrolytic capacitors, first place a dot of solder on one pad. Hold the capacitor in place and reheat this solder dot until it melts and flows onto the component. While the solder is still liquid you can adjust the alignment of the component. Lastly, solder the second pad of the capacitor as you normally would. When fitting the MOSFET transistor, be sure to orient the component correctly using the image to the left as a reference. Now it is time to fit R6 and D8.
Assembly Manual IV-12 VFD-Uhr Jenny
Page 3 of 8
(We will install the six RGB LEDs momentarily. For now, please do not install the column LEDs.) Note: On your pcb these six RGB LEDs can already be selected, tested and fitted. First, fit all six LEDs into their holes and check for correct orientation. Now bend the outer two leads a little bit as this bend will hold the LEDs when turning the board. Solder only one outer lead of each LED as quick as possible and use as little solder as possible. Beware of the small clearance for each pad. Now cut all the leads to a length of 1mm. Verify that each LED is absolutely perpendicular to the board and that each one has complete contact with the surface. If necessary, you may reheat pads to adjust positioning. At this point, you may solder carefully all of the remaining pads. It is a good idea to check for solder jumps. This stage can be particularly problematic. Now, we have to add also some “real” solder jumps as shown in the pictures: X1-X2 and X7-X8 supply the filament voltage and X9-X10 supply the voltage by connecting the anode voltage to the source drivers. Now it’s time for a brief voltage and function test. Before you begin, double-check the polarity of all capacitors, diodes, transistors and integrated circuits. Additionally, check the bottom of the PCB for unintentional solder connections.
Now, plug the power supply and turn it on. Does a part run hot or is there a burning smell? If so, pull out the DC plug immediately and look for the fault. At this stage, the board draws around 1.5VA so nothing should be generating significant heat. If everything appears to be correct, pick up the probes from your multimeter. For our testing purposes, the GND test pin is used as reference for all voltage measurements. Check voltage on TP1 for 5.7V. This is the supply voltage for both PIC processors and the 4511 decoder. If your measured voltage doesn’t match the range from 5.5 to 6.0V check all of the parts around IC1 and verify the orientation of D5. If IC1 runs hot, check for short circuits. Check voltage on TP2 for 2.5V. This is the generated filament voltage* from the step down converter on the left side of the board. If the voltage is not in the range of 2.4 to 2.7V check all parts around IC3. Additionally, verify that you have the right component in D7 and that it is correctly oriented. Lastly, ensure that the capacitors C12 and C13 are not mismatched. * Normally the filament voltage of the tubes is 1.5V. Some more words about this trick at the end of the manual. Check voltage on TP3 for 43V. This is the generated anode and gate voltage from the step up converter in the middle of the board. If the voltage is not in the range of 41 to 45V check all of the parts around IC4 and ensure the correct orientation of the MOSFET transistor behind IC4.
Assembly Manual IV-12 VFD-Uhr Jenny
Page 4 of 8
Tip: By de-soldering jumper X9-X10 you can completely disable the voltage flow to the source drivers IC7 and IC9. This may help troubleshooting (checking for short circuits) if e.g. resistor R4 runs hot. If this happens, check C21 and C26 for correct voltages and IC7 and IC9 for solder joins between their leads. Please note that these ICs are not short circuit proof. Therefore R4 is added to limit the current in such a fault. Please do not proceed beyond this point if any of the check points are not within their specified range. If everything is working, disconnect the power supply. Now we will check the function of the six RGB-LEDs. First, plug in PIC processor IC5; check for correct orientation and plug in the power supply again. Now the PIC should start its first sequence beginning with red color followed by purple blue cyan green yellow. Ensure that all LEDs light up. If a color is missing from any or all of the LEDs or a wrong color lights up during the sequence, it is likely that you have a solder jump between LED pads. Double-check your work using a loupe. Please do not proceed until you have found the fault! If the above test is completed successfully, we will proceed to install the column LEDs. To begin, thread both RGB LEDs through their spacers (4 x 10mm or 2 x 20mm) and fit the assembly carefully at the board. Solder only one lead of the LED and check to ensure that the diode is perpendicular to the leads in all directions. If necessary, reheat the pad and readjust the LED. Next, trim all of the leads and solder the remaining pads. Now place the four push button switches and the clock controller IC6. Ok, take a “panorama view” across your desktop. Are there some remaining electrical (!) parts except the 100nF capacitor we will need later? Let’s do an electrical check again, so reconnect the power. Now the column LEDs should flash once per second. Briefly push the button “Alarm”. LED9 behind this switch should light up red. If the above test is successful, it is time to fit the tube sockets. First, put on the supplied gloves and position the tube socket holder (pick one of the clear pieces - they are both the same). Be sure to remove the protective film from both sides. Don’t panic, this holder will fit perfectly. If it fails, check for some tight parts and bend them slightly but be gentle! Now it is time to begin assembling the enclosure. Use the photos below as a reference for these steps. First we will fix the socket holder close with the board. Use four supplied M3x12 spacers and four M3x12 bolts and mount them into the nuts. Fasten them carefully and only hand-tight. Now, we need to add an extra spacer for proper fitting the tube socket pins with the long legs of the tube. Simply place the board on the second spacer. Do not yet, however, remove the protective cover from this Plexiglas spacer.
Assembly Manual IV-12 VFD-Uhr Jenny
Page 5 of 8
Now apply 10 pins in each socket. If they are installed correctly, they should protrude about one millimeter from the socket holder (see left picture). You may need to “help” them a little bit by carefully pushing on the top of them. If you accidentally destroy a pin, don’t panic. There are extra pins included in the kit. When you are finished setting the pins, you will need three strips of adhesive tape to secure the sockets and prevent the pins from falling out when you flip the assembly upside down to solder it.
At this point, you may start soldering the pins in place. Be careful, if the pins get too hot they will melt the Plexiglas sockets. Next, cut all the short parts off of the tube pins leads. Now you will need to solder one more jumper. Connect X11 to X12. This completes the electrical circuit for the SuperCap. Lastly we must solder the remaining 100nF 50V
capacitor C30 from the solder side in parallel to R19 (see picture). Take care not to short circuit the switch’s pads next to the capacitors leads. Unfortunately this capacitor C30 has been added after finishing the production of the pcb. Now we can finally start to assemble the whole clock. To begin this step, remove the four bolts and spacers from the auxiliary construction. Then remove all of the protective film from the remaining four enclosure parts. Pick up the black casing bottom and one M3x12 bolt. Place the bolt through the middle hole in the bottom of the black Plexiglas board through the black spacer panel and into the board assembly. Thread the spacer onto the bolt from the board side and hand tighten. Complete fastening the remaining four bolts and spacers at the edges of the assembled board/socket combination in the same manner. Now, fit the second Plexiglas spacer on top of the device. The last part is the flat Plexiglas top and then use the (5) M3x6 bolts down from the top into the spacers to complete fastening. Lastly, adhere the five supplied transparent rubber feet on the button of the clock for stability. After carefully fitting the six IV-12 tubes into their sockets you can now enjoy your masterpiece. Well done! * The IV-12 tubes need a slightly negative potential of the gate (ca. -0.7V) vs. the cathode to completely disable the display. Therefore the potential of the filament is lifted with the two diodes D17+D18 at around 1V vs. ground. As the filament voltage’s reference is ground, this voltage must also lift up. So the step-down converter generates this 2.5V. When the tube is now completely disabled (the corresponding driver within IC7 has a high impedance) the tube “sees” through the 100kohms pull down resistor within the array on its gate around -1.0V with respect to the cathode / filament. Version as from 28/11/2010 • Final translation by Mathew Beall
Assembly Manual IV-12 VFD-Uhr Jenny
Page 7 of 8
Stückliste / part list Inhalt
Content Bauteile Description
Code Ref.
Stück Pieces
Multifuse PFRA 065 R2 1 DC-Buchse / DC Jack / 5,5 x 2,1mm BU1 1 Quarz / Crystal / 4.000MHz Q1 1 Piezo-Summer / Sounder SND1 1
1 Div.
Spule / Inductor / 22µH L1…L3 3 56R R1, R4, R6, R19, R25 5 590R R7, R10…R12, R23, R24 6 2k2 R3, R5, R9, R18, R20…R22 7 4k3 R17 1 10k R13…15 3 20k R8 1
2 Widerstände Resistors
9-Pin Array 8 x 100k RN1, RN2 2 27pF 50V Keramik C24, C25 2 220pF 50V Keramik C13, C17 2
100nF 50V Keramik C1…C5, C7, C12, C14, C18…C20, C22, C27, C29, C30 15
100nF 100V Keramik C21, C26 2 10µF 50V C23, C28 2 100µF 63V SMD „K-G“ C16 1 330µF 35V SMD „K-G“ C8, C9, C15 3
3 Kondensatoren Capacitors
1F 5V5 Goldcap C6 1 LED 5mm rot Flachkopf / Red Flat Hat LED9 1 LED 5mm RGB LED1…LED8 8 1N5819 D1…D4, D6, D7, D17, D18 8 1N4148 D5, D9…D11, D13…D15, D19 8
4 Dioden Diodes
UF4003 D8 1 BC337-40 / TO92 T2…T5 4 78L05 / TO92 IC1 1 IRLU024N N-MOSFET / I²PAC T1 1 MC34063A / 8-Pin DIL IC3, IC4 2 4511 / 16-Pin DIL IC8 1 TD62783 / 18-Pin DIL IC7, IC9 2 PIC16F628 / 18-Pin DIL IC6 1 IC-Sockel / IC-Socket / 18 Pin DIL für / for IC6 1 PIC12F629 / 8-Pin DIL IC5 1
5 ESD-Bauteile ESD Parts
IC-Sockel / IC-Socket / 8 Pin DIL für / for IC5 1 Drucktaster / Push Buttons S1…S4 4 Distanz / Spacer M3 x 12 5 Schraube Stahl / Screw Steel / M3x12 5 Schraube Stahl / Screw Steel M3x6 5 Selbstklebefüße / Rubber Feeds
für Gehäusemontage for enclosure assembly
5
6 Mechanik Mechanics
Distanz / Spacer 4.2x10 oder / or 4.2x20 für / for LED7, LED8 4 o. 2 7 Röhrensockel-Stifte / Tube Socket Pins 60 ++ 8 Röhren in Schachteln / Tubes in boxes / IV-12 6 + 1 9 Leiterplatte / PCB 1 10 Gehäuse komplett / Complete Enclosure 1 Set 11 Baumwoll-Handschuhe / Cotton Gloves 1 P. 12 Biegelehre / Lead forming tool 1 13 Schaltnetzteil / Switching Power Supply 1 14 Gedruckte Bauanleitung / Printed Assembly Manual 1 15 Gedruckte Bedienungsanleitung / Printed Owners Manual 1
R6 und D8 später bestücken (siehe Text)Fit R6 and D8 later (see text)
PIC12F629
MC34063A
MC34063A
TD62783APTD62783AP4511
+ –
+–
Bitte die Ausrichtung der Spulen beachtenPlease take care of the inductor's orientation
+330µ
330µ
Q1
PIC 16F628
WiderständeResistors56R
590R
2k2
4k3
10k
20k
ZeichenPicture
CodeRef.
Stückpcs.
R1, R4, R6, R19, R25
R7, R10, R11, R12, R23, R24
R3, R5, R9, R18, R20, R21, R22
R17
R13, R14, R15
R8
Array 8 x 100k
BemerkungenRemarks
RN1, RN2
5
6
71
3
1
2 Ausrichtung!Orientation!
DiodenDiodes
ZeichenPicture
CodeRef.
Stückpcs.
BemerkungenRemarks
1N5819 D1, D2, D3, D4, D6, D7, D17, D18 8
1N4148 D5, D9, D10, D11, D13, D14, D15, D19
UF4003 D8
Ausrichtung!Orientation!8
1
KondensatorenCapacitors
ZeichenPicture
CodeRef.
Stückpcs.
27pF "27" C24, C25 2
220pF "n22"
100nF 50V "104"
C13, C17
C1…C5, C7, C12, C14, C18…C20, C22, C27, C29, C30
2
15
100nF 100V "104" C21, C26 2
10µF min. 50V + – C23, C28
100µ
100µ C16
330µ
330µ C8, C9, C15
100µF 50V SMD
330µF 35V SMD
+ –
+ –1F 5V5 GoldCap C6
Ausrichtung!Orientation!
2
1
3
1
HalbleiterSemiconductors
ZeichenPicture
CodeRef.
BC337-40
78L05
T2, T3, T4, T5
IC1
Stückpcs.4
1
C30 parallel zu R19 von der Lötseite her anlötenSolder C30 in parallel to R19 from the solder side
5
5
4
4
3
3
2
2
1
1
D D
C C
B B
A A
+HV
5V7
5V4
5V7 5V4
5V7
FIL
+HV
FIL
Title
Size Document Number Rev
Date: Sheet of
VFD-Clock Jenny.obj 10.2010
IV-12 VFD-Clock Jenny
<OrgName>
1 1Tuesday, September 21, 2010
Title
Size Document Number Rev
Date: Sheet of
VFD-Clock Jenny.obj 10.2010
IV-12 VFD-Clock Jenny
<OrgName>
1 1Tuesday, September 21, 2010
Title
Size Document Number Rev
Date: Sheet of
VFD-Clock Jenny.obj 10.2010
IV-12 VFD-Clock Jenny
<OrgName>
1 1Tuesday, September 21, 2010
10er h
1er h
10er m
1er m
10er s
1er s
BGA
R
25V
Track 0R2
50V
100V
100V
5V5
C30100nKC30100nK
LED3 RGBLED3 RGBRGB
A
D11 1N4148D11 1N4148X10X10
C12100nKC12100nK
D191N4148D191N4148
BU
1B
U1
D3
1N5819
D3
1N5819
IC5PIC12F629IC5PIC12F629
VDD1GP52GP43MC4
VSS 8GP0 7GP1 6GP2 5
T2BC337T2BC337
LED7RGB LED7RGBRGB
A
X12X12
R23590R
R23590R
C15330µC15330µ
C3100nKC3100nK
D10 1N4148D10 1N4148
GNDGND
X4X4
C14100nK
C14100nK
RN2100kRN2100k
R2556RR2556R
a
b
c
d
e
f g
H6 IV-12
a
b
c
d
e
f g
H6 IV-12
G4
c 6
g 9
b 7Fl3
a 8
f 10e 1d 5Fl2
LED6 RGBLED6 RGBRGB
A
C26100nK
C26100nK
IC7TD62783APIC7TD62783AP
In11In22In33In44In55In66In77In88VS9 GND 10Out8 11Out7 12Out6 13Out5 14Out4 15Out3 16Out2 17Out1 18
TP2TP2
R656RR656R
C4
100n
KC
410
0nK
C13220pC13220p
R1510kR1510k
TP3TP3
R14
10k
R14
10k
C18100nKC18100nK
L222µH
L222µH
C2100nK
C2100nK
IC6PIC16F628A Clock-ControllerIC6PIC16F628A Clock-Controller
BCD-C 1BCD-D 2
BCD-A 17BCD-B 18
NEONS 3
HRSx10 11HRSx1 10
MINSx10 9MINSx1+ADV 8
SECSx10+SET 7SECSx1+MODE 6SOUND13
MCLR4
KEY-INPUT12
XTAL115
XTAL216
VDD14
GND5SND1SND1
C2310µC2310µ
D14
1N41
48D
141N
4148
R10590RR10590R
T3BC337T3BC337
LED4 RGBLED4 RGBRGB
A
X9X9
a
b
c
d
e
f g
H1 IV-12
a
b
c
d
e
f g
H1 IV-12
G4
c 6
g 9
b 7Fl3
a 8
f 10e 1d 5Fl2
R820kR820k
LED8RGB LED8RGBRGB
A
LED2 RGBLED2 RGBRGB
A
C19100nK
C19100nK
D5
1N41
48D
51N
4148
S4AdjustS4Adjust
R156RR156R
R456RR456RS3
SetS3Set
X6X6
TP1TP1
LED1 RGBLED1 RGBRGB
A
D9 1N4148D9 1N4148
D1
1N5819
D1
1N5819
D15
1N41
48D
151N
4148
IC1 78L05IC1 78L05
INGND
OUT
R1956RR1956R
a
b
c
d
e
f g
H2 IV-12
a
b
c
d
e
f g
H2 IV-12
G4
c 6
g 9
b 7Fl3
a 8
f 10e 1d 5Fl2
T1IR
LU02
4NT1IR
LU02
4N
a
b
cde
f g
IC84511
a
b
cde
f g
IC84511
A7B1C2D6
VD
D16
VS
S8
LE5
LT3
Qa 13Qb 12Qc 11Qd 10Qe 9Qf 15
Qg 14BL4
C20100nK
C20100nK
R92k2R92k2
X3X3D7
1N5819D7
1N5819
C2427pKC2427pK
R12590RR12590R
T4BC337T4BC337
L1
22µH
L1
22µH
R52k2R52k2
IC3MC34063AIC3MC34063A
SC1SE2TC3GND4
DC 8IS 7
VCC 6CI 5
D8UF4003
D8UF4003
C29100nKC29100nK
D61N5819
D61N5819
IC9TD62783APIC9TD62783AP
In11In22In33In44In55In66In77In88VS9 GND 10Out8 11Out7 12Out6 13Out5 14Out4 15Out3 16Out2 17Out1 18
C61FC61F
X8X8
X11X11
R222k2R222k2
C16100µC16100µ
a
b
c
d
e
f g
H3 IV-12
a
b
c
d
e
f g
H3 IV-12
G4
c 6
g 9
b 7Fl3
a 8
f 10e 1d 5Fl2
C7100nKC7100nK
D181N5819
D181N5819
C22
100nK
C22
100nK
R2PFRA 065R2PFRA 065
R13
10k
R13
10k
L3
22µH
L3
22µH
C17220pC17220p
R7
590R
R7
590R
C9330µC9330µ
R212k2R212k2
D171N5819
D171N5819
LED5 RGBLED5 RGBRGB
A
S2ModeS2Mode
S1LED Prg.
S1LED Prg.
T5BC337T5BC337
C8
330µ
C8
330µ
R174k3R174k3
X5X5
Q14.000MHz
Q14.000MHz
R182k2R182k2
C5100nKC5100nK
LED9AlarmLED9Alarm
C27100nKC27100nK
a
b
c
d
e
f g
H4 IV-12
a
b
c
d
e
f g
H4 IV-12
G4
c 6
g 9
b 7Fl3
a 8
f 10e 1d 5Fl2
X2X2
IC4MC34063AIC4MC34063A
SC1SE2TC3GND4
DC 8IS 7
VCC 6CI 5
C21100nK
C21100nK
X1X1
C1100nKC1100nK
D13
1N41
48D
131N
4148
RN1 100kRN1 100k
R11590RR11590R
C2527pKC2527pK
a
b
c
d
e
f g
H5 IV-12
a
b
c
d
e
f g
H5 IV-12
G4
c 6
g 9
b 7Fl3
a 8
f 10e 1d 5Fl2
X7X7
C2810µC2810µ
R32k2R32k2
D2
1N5819
D2
1N5819
R24590RR24590R
R202k2R202k2
D4
1N5819
D4
1N5819
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