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Assembly Manual IV-12 VFD-Uhr Jenny

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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.


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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.


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(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.


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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.


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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


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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


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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


Date: Sheet of



<OrgName>


Title


Date: Sheet of



<OrgName>


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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