assembly manual „leon“ usb powered nixie clocks · parts runs hot. if everything is allright we...
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Assembly Manual „Leon“ USB powered Nixie Clocks
Congratulations for purchasing this Nixie clock kit “Leon”.For successful assembly of this kit please read the following helpful hints.
• This kit is designed for someone who has advanced experience with assemblingelectronics.• If you believe that the kit is too complicated for your skill level please do not try toassemble it - this generally ends up with a device that is not repairable and results in youbeing very frustrated. Please contact the provider and they can offer you other options thatwill end in a more fulfilling result!• Take your time - this kit should take 2 hours to complete if uninterrupted. Assemblingthe kit in a hurry will lead to frustration and troubleshooting takes three times as long.• Ensure your work area is well lit (daylight preferred) and clean.• Electronic tools, such as pliers, small side-cutters or tweezers will be handy. You willalso need a T10 (Torx) Allen screwdriver for the housing assembly.• A soldering iron station with a 1 mm round tip (maximum) and a 0.5 mm (maximum)fine electronic solder (lead-free) is required. For lead-free solder we’ve had goodexperience with type Iso-Core EL Sn95,5 Ag3,8 Cu0,7 with 0,5 mm Ø and 3,5% Flux fromFelder Löttechnik and a 400°C soldering tip temperature.• For the intermediary function test you need a multimeter with at least 200 VDC range.• A loupe (magnifying glass) to read the small device markings is often helpful.• Assemble the board in the order as stated in the instructions - this has been proven andwill minimise mistakes.• It is assumed that you understand that semiconductors (diodes, ICs, transistors) orelectrolytic capacitors are polarized components. Appropriate markings are silk-screenedon the PCB and shown on the board schematic.
Together with this construction guide there are some other usefull documents fordownload
• The owners manual for this “Leon” Nixie clock kit• Schematic and Parts List
Safety precautions:During assembly, operation, measurements and maintenance extra precautions mustbe taken. The generated high voltage of 160 V is dangerous. Assemble the circuit at yourown risk.The clock’s functionality cannot be guaranteed when assembled by the customer.No responsibility can be taken for any personal claims and damages during assemblyand commission, especially for damages based on insufficient technical knowledge.The Nixie clock may only be operated in a solid and moisture-proof enclosure.The person who completes the kit and assembles this board into an enclosure foroperation is considered by the German directive VDE 0869 as a manufacturer and isrequired to indicate their name and address including all documents when selling theclock.Ready-to-go devices, which are assembled from kits, are counted as a safety-relatedindustrial made product.
Okay, and now, Ladies and Gentlemen – start your soldering iron...
Following fit and solder the 28-pol. IC socket, the crystal, the potentiometer and the buzzer. Thepolarity marking on the buzzer is negligable.
Start with soldering the 32-pol. female header, fitted from the solder side
As you might notice, most of the electrical parts are just pre-assembled and soldered.However, we recommend to check these SMT assembly for assembly faults and cold solder padsbefore assembling the through hole components.You’ll find at the end of the manual a detailed assembly silk screen for reference.
Next cut and remove the tape from the 2.200μFcapacitor. Please do not simple cut the wires atthe top of the tape as the remaining lenght willbe too short.
Pin 1
Pin 14
Pin 15
Pin 28
Solder these two outer pins also from this (solder) side !
Assembly Manual „Leon“ USB powered Nixie Clocks
Now connect the PCB to an USB power supply and check if something strange will happen; e.g. aparts runs hot. If everything is allright we will do follwing some voltage checkings:
Please check the voltages on the PIC’s socket pins with a multimeter. Put the negative probe (black)on TP3; left hand from the buzzer. Put the positive probe (red) on the socket pins.
Measured Voltagesred = ca. 5 V • blue = 0...3 V • amber = 0,3 V • green = ca. 0...-2 V • black = 0 V
Pin 1 • Pin 2 • Pin 3 • Pin 4 • Pin 5 • Pin 6 • Pin 7 • Pin 8 • Pin 9 • Pin 10 • Pin 11 • Pin 12 • Pin 13Pin 14 • Pin 15 • Pin 16 • Pin 17 • Pin 18 • Pin 19 • Pin 20 • Pin 21 • Pin 22 • Pin 23 • Pin 24Pin 25 • Pin 26 • Pin 27 • Pin 28
Check following the voltages on the other testpoints: TP1 (around 4.5 V) • TP2 (around 3 V)Please do not proceed until all voltages are within their range and check for the fault.
If everything is ok, unplug the clock from the power supply.
Solder now jumper „ENABLE HIGH V. CONVERTER“ X1/X2, direct above the inductorand insert the PIC. Keep care for correct orientation. Turn on the clock again.
Caution! Now the HV converter is working. Therefore 170 V is present on the board.
Please check again, if something strange happens; e.g. if a part will run hot.Pick up now a screwdriver and do again a measurement of the voltage on TP1It should be in the range of 40 V.
Adjust now this voltage with potentiometer „HIGH V. ADJUST“ to 41.5 V
Do following a voltage check on TP2. It should be in the range of 170 V.Push now button SET. The clock must make a short bleep.Unplug the clock again from power and wait 10 secs. until the capacitors are discharged.
Stop here and flip the page. You need now assemble and fit the tube board. Whenfinished come back for a quick test of the tube board.
Turn the clock on again.The tubes should start with a „digit test routine“; which counts all digits. Also the (RGB) LEDs arechecked within this routine with the following scheme:
Digit 1 = red • digit 2 = green • digit 3 = blue • digit 4 = none • digit 5 = green/orangedigit 6 = none • digit 7 = violett • digit 8 = none • digit 9 = cyan • digit 0 = none
The column Neons should continuously light up and slightly flicker.
If everything is ok, unplug the clock again from power.
Solder now jumper „ENABLE POWER BACKUP“ X3/X4 direct below the dual LEDs.
Solder jumper A/B direct below the ASK module.
Now flip the page again and assemble the enclosure to finish your clock.
Pick up the mounting bracket, the 2,9 x 9,5metall tapping screw and two rosettes.
Mount the bracket as shown in the picture.
Assemble now the 2.200μFcapacitor as shown in thepicture.Tip: Solder from componentside.Assemble following theremaining 2,2μF capacitor.Take care for correctorientation.
Assemble following both dual LEDs (pay attention for correct colour), the Super Capacitor(pay attention for the polarity / arrow marking) and both dual switches.
On the white mainboard (Rev.10/2012) these 10μF are SMT type and just pre-assembled
Assembly Manual „Leon“ USB powered Nixie Clocks
Assembling the Leon Tube Board
1.: Start with assembling the tubesocket pins and both 510k resistors.
2.: When finished fix the pins and resistorswith a piece of self-adhesive tape.
3.: Flip the board and solder all pins and both resistors
7.: Pick up the RGB-LEDs and bend them asshown in the picture. Keep special careabout the location of the Anode wire (longestwire)
4.: Pick up the neons, bend the leads straight and add two 8 mm spacers.
5.: Bend the neon’s wires as shown in thepicture. Do not make any short ciruit.
6.: Add carefully all tubes and neons to theboard and solder the neons.
8.: Fit the LEDs to the board and solderthem. Use as less solder tin as possible asthe spacing between the LED pins is verysmall.
9.: Fit the 32-pin header and the resistorarrays (the „polarity“ is negligable) fromsolder side and solder them.
10.: Attach the tube board to the main board. Now solder with a piece of (cutted) wire aconnection between pin „HV“ of the tube board to „TP2“ on the main board. This will feedthe 170V, which are necessary to power the neons, to the tube board.
Stop here: Turn back to the assembly of the main board for a quick functioncheck of the tube board.
Assembling the Leon Enclosure
Pick up the front cover, remove both protective films and attach the cover on thealuminium profiles. Now fix the cover only with 3 screws GF M3 x 14 and tighten loosethe right hand screw.
Assembly Manual „Leon“ USB powered Nixie Clocks
Next pick up both reinforcement profiles and attach them to the enclosure. To enable thisyou need to bend the (only with one screw fixed) right hand profile a little bit.
Remove all protective films from bothtransparent covers and from the silverycover. Keep special care to remove only the„inner“ film on the self-adhesive side fromthe silvery cover.
Attach next the transparent coverson the self-adhesive side. Check forproper alignment befor this task as iiis very difficult to remove this coverswhen fixed.
Pick up next the rubber grommet and insertit into the hole of the buttom cover.
Attach now the 5/8“ to 3/8“ adaptertogether with the nut.
!
Attach both covers to the enclosure. Add the remaining screw on the front cover andtighten them.
Attach now two red „ears“ and fixthem with the GF M3 x 20 screws.
Remove from the rear cover the protectivefilm from the self-adhesive side (theengraved outer side has no film) and fix it onthe main board with the M3 x 6 screw
Assembly Manual „Leon“ USB powered Nixie Clocks
Next remove the buttom cover from the enclosure and add the electronics plus areinforcment profile as shown in the photo.
Add four rods to the aluminium profiles.Keep care about the correct orientation ofthe nut.Next add to the assembled top cover theremaining reinforement aluminium profile.
Slide carefully the electronics together withthe buttom cover into the enclosure. Checkif the neons will fit into their holes on front.Next fix the rear with the remaining 4 x GFM3 x 14 screws
Finally fit the remaining two „ears“ and fix them.Congratulations. Your clock is now ready assembled. Have a lot of fun.
Adding the ASK Receiver Module from the„Wireless GPS Connection“
Simply fit the module onto the mainboard and solder the 8 pins.Pay attention for correct orientation (see pictures).
The clock has a build in antenna. However, due to the RF shielding of the aluminium profiles thereception range is very limited. If the reception is too poor you can connect the supplied external
antenna to the TIME DATA connector.
Don’t forget to set option #12 to value 4 (for GPS reception) and option #14...16 to correct the timeoffset according to your location; this offset is based on standard time (not day saving).
The green LED below the module will show the received data as well as the DATA LED on rear.
Please note that it is not possible to connect an extra external receiver to the TIME DATAconnector when an ASK module is fitted, only the supplied antenna can be fitted.Please check also, if the solder jumper A/B (direct below the module) is soldered.
For setting up the „Wireless GPS Connection“ system proceed as stated in the appropriateowners manual.
Anbieterkennzeichung • VendorJürgen Grau • Feiningerweg 28/1 • 72622 Nürtingen • Germany • Fon: 07022 / 789 6886 • Fax: 07022 / 90 44 03
E-Mail: [email protected] • www.Nixiekits.eu
Subject change without notice – Issue 1.0 – Version from 03.10.2014
DateMarch, 10th. 2013
Issue1.0
DescriptionInitial Release
Revision History
5
5
4
4
3
3
2
2
1
1
D D
C C
B B
A A
K10K9K8K7K6K5K4K3K2K1
KK10KK9KK8KK7KK6KK5KK4KK3KK2KK1
KK8KK7KK6KK5KK4KK3KK2KK1
KK10KK9
A1
A2
A3
A4
A5
A6
A3
A5K2K3K4K5K6
K8K7
K9
KK1KK2KK3KK4
KK6
KK7KK8KK9KK10
AM
VC
PM
LR
LG
LB
LB
LG
LRA1
LB
A4
K10K9K8K7K6K5K4K3K2K1
K10K9K8K7K6K5K4K3K2K1
LG
LR
LR
LG
LB
A2
A6
VC
LR
LG
LBVC
LR
LG
LB
LR
LG
LB
VC
VC
AM
AM
VCPM
PM KK8KK7KK6KK5KK4KK3KK2KK1
KK10KK9
VC
K1K10
KK5
DCF
DCF
DCF
VCC
VCC
VCC
VCC
VCC
Title
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Title
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USB powered Nixie Clock
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POLARITY
HV ENABLE
BACKUPENABLE
HV ADJUST
63V 63V
6V3
Track 17,4 cm
22 x 560R 0603
IN-2 Laura Tube Board
- +
TR122k
- +
TR122k
H1H1
A
0987654321
N13N13
T101DT101D
R2R2
R23
12k
R23
12k
LED8LED8
NPMNPM
R20R20
L2L2
M3M3
MA4MA4
TP1TP1
R19R19
C91uC91u
N14N14
IC2HV5812IC2HV5812
VHV1
DOUT2
HV20 3
HV19 4
HV18 5
HV17 6
HV16 7
HV15 8
HV14 9
HV13 10
HV12 11
BLANK13
GND14
CLK15
STROBE16 HV11 12
HV10 17
HV9 18
HV8 19
HV7 20
HV6 21
HV5 22
HV4 23
HV3 24
HV2 25
HV1 26
VDD28
DATA27
BU1
DCF/GPS
BU1
DCF/GPS
L7L7
R12R12
LED3LED3RGB
A
R2612kR2612k
T61DT61D
R27470RR27470R
NLGNLG
Q132kQ132k
S1S1
MAMMAM
R32680kR32680k
M20M20
M12M12
M8M8
R50
12k
R50
12k
NAMNAM
T122DT122D
R46
470R
R46
470R
N15N15
T81DT81D
C1
33p
C1
33p
NA4NA4
C162u2C162u2
R22R22
D8
SS16L
D8
SS16L
M11M11
D5
SS16L
D5
SS16L
CC
T132DT132D
R572k7R572k7
M6M6
C2710uC2710u
R4R4
R41470RR41470R
LED5LED5RGB
A
R14R14
R10R10
T151DT151D
TP3TP3
N16N16
C12
1u
C12
1u
R3812kR3812k
N5N5
X4X4
C1310uC1310u
X1X1
C20
1u
C20
1u
LED13LED13
M15M15
R62
12k
R62
12k
N20N20
L4L4
C2510uC2510u
N18N18
LED7LED7
M2M2
R52
680k
R52
680k
D2
SS16L
D2
SS16L
R3R3
M18M18
OP
TIO
NA
L1
AS
K-R
XB
2O
PT
ION
AL
1A
SK
-RX
B2
GNDSHTDAT5V
5VGNDGNDANT
R53
680k
R53
680k
LED6LED6RGB
A
R6R6
NA1NA1
R18R18
R49
12k
R49
12k
X3X3
BB
R25
12k
R25
12k
NA2NA2
C51uC51u
T41DT41D
T112DT112D
NA5NA5
R44
12k
R44
12k
LED4LED4RGB
A
R8R8
R48
12k
R48
12k
M9M9
R582k7R582k7
NLBNLB
IC1
PIC16F1938_IN-2
IC1
PIC16F1938_IN-2
MCLR1
HV SENSE2
A1 28
LED B 27LED G 26LED R 25
A3 7
VS
S8
LED AM 9
LED PM 10
XTAL1/TCXO11
XTAL212
HV PWM13LED DST 14
LED ALARM 15
LED DCF/GPS 16
SOUNDER17
DCF/GPS18
VS
S1
9V
DD
20
SET21
ADJ22
ALARM23
DST24
DTA 3
CLK 4
STR 5
A2 6
R45
470R
R45
470R
N6N6
R42470RR42470R
NVCNVC
R16R16
LED9LED9
M5M5
NA6NA6
C101uC101u
MA5MA5
T21DT21D
R21R21
MA3MA3
M13M13
R37n.c.R37n.c.
MVCMVC
C8
10u
C8
10u
SND1SounderSND1Sounder
N7N7
LED2LED2RGB
A
R13R13
T11DT11D
R7R7
C151uC151u
M1M1
R30680kR30680k
R34680kR34680k
L6L6
N8N8
M16M16
N19N19
AA
C171FC171F
R29680kR29680k
C42200uC42200u
R47
470R
R47
470R
R3912kR3912k
L1L1
R592k7R592k7
R15R15
MLGMLG
R5R5
C18
1u
C18
1u
R36
12k
R36
12k
N9N9
X2X2
N1N1
BU2BU212345
T71DT71D
M19M19LED12LED12
T31DT31D
D6
SS16L
D6
SS16L
MA2MA2
T14NDT3055LT14NDT3055L
MA1MA1
C2610uC2610u
R552k7R552k7
H5H5
A
0987654321
R1R1
NA3NA3
M4M4
N10N10
R33
680k
R33
680k
N2N2
R51
680k
R51
680k
R9R9
D7SS16LD7SS16L
S2S2
LED10LED10
H4H4
A
0987654321
R24
12k
R24
12k
R562k7R562k7
M14M14
MLRMLR
C24
1u
C24
1u
L847uHL847uH
T51DT51D
R542k7R542k7
D3
SS16L
D3
SS16L
MA6MA6
R43
12k
R43
12k
C733pC733p
ZD175VZD175V
LED11LED11
C2233pC2233p
D1
SS16L
D1
SS16L
N11N11
N3N3
D4
SS16L
D4
SS16L
R35
12k
R35
12k
M10M10
M7M7
H3H3
A
0987654321
TP2TP2
C2133pC2133p
C19
10u
C19
10u
L5L5
H6H6
A
0987654321
MLBMLB
Z1Z1
NLRNLR
R17R17
R11R11
H2H2
A
0987654321
C141uC141u
N12N12
C2333pC2333p
R40470RR40470R
R60470RR60470R N4N4
MPMMPM
R63470RR63470R
R3112kR3112k
R61
12k
R61
12k
R28680kR28680k
LED1LED1RGB
A
M17M17
T91DT91D
N17N17
L3L3
C6
10u
C6
10u
C310uC310u
C111uC111u
5
5
4
4
3
3
2
2
1
1
D D
C C
B B
A A
A3
KK8KK7KK6KK5KK4KK3KK2KK1
KK9
A4A5
A1
KK9KK8KK7
K9
AM
KK6
K8
KK5
VC
K7
KK8KK7KK6KK5KK4KK3KK2KK1
KK9
KK4
PM
K6
KK3
K5
KK2
K4
KK1
R
K3
K9K8K7K6K5K4K3K2K1
K2
G
BK1
K9K8K7K6K5K4K3K2K1
B
G
R
A1A2
VC
K0
K0
B
G
RA2
VC
G
BVC
K0
A3R
HVAM
A4R
G
BVC
KK0
PM HV
A5R
G
BVC
KK0
A6R
G
BVC
KK0
A6K0K1K2K3K4K5K6KK7KK8KK9KK0KK1KK2KK3KK4KK5KK6K7K8K9
HV
Title
Size Document Number Rev
Date: Sheet of
For USB Nixie Clock Main Board 0
Leon Tube Board
1 1Saturday, February 23, 2013
Title
Size Document Number Rev
Date: Sheet of
For USB Nixie Clock Main Board 0
Leon Tube Board
1 1Saturday, February 23, 2013
Title
Size Document Number Rev
Date: Sheet of
For USB Nixie Clock Main Board 0
Leon Tube Board
1 1Saturday, February 23, 2013
RN1...6 = 3 x 1k Array
H4ST12CH4ST12C
A
0987654321
HVHV
NPMNPM
RN2ARN2A
LED6LED6RGB
A
RN1ARN1A
R2
510k
R2
510k
N2N2
NA2NA2
RN6BRN6B
N7N7
N20N20
RN4ARN4A
N10N10
N6N6
NLGNLG
H7H7
LED2LED2RGB
A
R1
510k
R1
510k
N17N17
N16N16
RN2BRN2B
NVCNVC
NLBNLB
N3N3
H8H8
H3ST12CH3ST12C
A
0987654321
N13N13
H5ST12CH5ST12C
A
0987654321
RN1BRN1B
RN2CRN2C
NA3NA3
NLRNLR
N1N1
NA6NA6
NAMNAM
NA1NA1
H1ST12CH1ST12C
A
0987654321
N14N14
N8N8
RN3ARN3A
H6ST12CH6ST12C
A
0987654321
RN4CRN4C
RN5BRN5B
RN1CRN1C
NA4NA4
N19N19
LED5LED5RGB
A
LED1LED1RGB
A
RN6CRN6C
RN5ARN5A
H2ST12CH2ST12C
A
0987654321
N11N11
N4N4
RN3BRN3B
N5N5
RN5CRN5C
N9N9
N15N15
N18N18
RN3CRN3C
LED4LED4RGB
ARN4BRN4B
N12N12
RN6ARN6A
NA5NA5
LED3LED3RGB
A
Part List Leon USB powered Nixie Clock
Through hole components Main PCB for Leon Qty Part description Value Position / Code 1 Duo-LED Green / green LED11 1 Duo-LED Red / Yellow LED12 4 LED spacer 8 mm Tube Board 2 Dual push button switch S1, S2 1 Buzzer 42 ohms voice coil imp. SND1 1 Super Capacitor 1F 5V5 C17 1 Electrolytic capacitor 2200uF 6V3 C4 1 Electrolytic capacitor 2u2 250V C16 1 Potentiometer 22k TR1 1 Crystal 32.756 kHz Q1 1 IC-Socket 28-pol. IC1 1 Processor 16F1938 IC1 1 Female Connector 90° 32-pol. 32-pol. 1 Male Connector 180° 32-pol. 32-pol. 1 Mounting Bracket M3 / 3.2 1 Allan flat hat screw M3 x 6 1 Sheet metal screw 2.9 x 9.5 1 Rosettes Plastic black 1 Main Board Board preassembled Electrical and Mechanical Parts for Leon Nixie Clock Tube Board Ca. 70 Tube socket pins H1…H6 8 Alan flat hat screw self tapping M3 x 14 4 Alan flat hat screw self tapping M3 x 20 4 Roads Red plastic 6 RGB-LEDs 5mm diffus LED1…LED6 2 Neons H7,H8 2 Resistors 510k R1,R2 6 Resistor Arrays 1k RN1…RN6 2 Aluminium side profiles 1 Rubber grommet 1 5/8” to 3/8” adapter 1 Nut for adapter 4 “Ears” Red plastic 4 Aluminium rainforcement frames 1 Leon Tube Board 1 Front cover 1,6 mm silvery 1 Rear cover 1,6 mm silvery engraved 1 Top cover 1,6 mm silvery 1 Bottom cover 1,6 mm silvery with drill hole for adapter 2 Reinforcement frames 3 mm transparent with drill hole