GEKCO CLK056, Assembly & Operation Manual

Page 1: ...LOCK MODEL CLK056 ASSEMBLY OPERATION MANUAL GEKCO Inc 1565 SW Cypress Ln McMinnville OR 97128 503 472 4770 P N 595 325 REV 181030 Copyright 2018 GEKCO Inc All Rights Reserved Printed in the United States of America c ...

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Page 3: ... 3 SOLDERING 9 5 STEP BY STEP ASSEMBLY 10 5 1 DISPLAY CIRCUIT BOARD 10 5 2 MAIN CIRCUIT BOARD 14 6 INITIAL TESTS 16 7 FINAL TESTS 17 8 IN CASE OF DIFFICULTY 17 9 FINAL PCA ASSEMBLY 17 10 FINAL ASSEMBLY 17 11 THEORY OF OPERATION 20 11 1 BLOCK DIAGRAM 20 11 1 MAIN BOARD CIRCUIT DESCRIPTION 20 11 2 DISPLAY BOARD CIRCUIT DESCRIPTION 21 12 FIRMWARE 22 12 1 FLOW CHART 22 12 2 FIRMWARE DESIGN DESCRIPTION...

Page 4: ...ASSEMBLY PICTORIAL 12 FIGURE 5 MAIN BOARD COMPLETED ASSEMBLY 14 FIGURE 6 MAIN BOARD TOP VIEW 1 14 FIGURE 7 MAIN BOARD TOP VIEW 2 14 FIGURE 8 MAIN BOARD TOP VIEW 3 14 FIGURE 9 MAIN BOARD TOP VIEW 4 15 FIGURE 10 MAIN BOARD WITH STANDOFFS 15 FIGURE 11 MAIN AND DISPLAY BOARD INTERFACE CONNECTOR MOUNTING 15 FIGURE 12 RTC MODULE ASSEMBLY 17 FIGURE 13 ENCLOSURE BACK 18 FIGURE 14 ENCLOSURE BACK WITH TOP 1...

Page 5: ...sary information Also this design is fully open source for both the hardware and firmware There are full schematics and pictorial diagrams of the hardware also there are links and flowcharts of the firmware microcontroller code 2 Operational Summary The Model CLK056 has 6 digits of seven segment displays to display HOURS MINUTES and SECONDS The HOURS display can alternate between two time zones wh...

Page 6: ...o avoid misplacing parts 3 1 Top Level Parts List Remove the parts from the main bag and separate each individual parts bags ITEM QTY PART NO DESCRIPTION 1 1 DBR656 KIT Clock Display Board PCA parts bag 2 1 CLK056M KIT Clock Main Board PCA parts bag 3 1 2217625 Real Time Clock RTC Module DS3231 4 1 CLK056HDW KIT Final Assembly Hardware 5 1 CLK0X6ENC KIT Enclosure Acrylic 6 Piece 6 1 54 660 AC to D...

Page 7: ...splay Module 7 Segment 2 Digit 0 56 2 1 X1 434 3110 Socket IC Dip24 300 3 1 U1 442 3090 IC LED Display Driver MAX7219CNG 4 1 J1 131 1X10 Connector Header Single Row Male 10 pins 5 4 LED3 LED4 LED5 LED6 412 125 LED Red PCB Mount T1 3 4 6 1 C2 26 102 Cap elect alum radial lead 10uF 16v 7 1 C1 20 104 Cap mono Cer 50v radial lead 8 1 R1 6 1002 12 Res metal film 1 4w 1 10k 9 1 81 180911D PCB Display Bo...

Page 8: ...fier 1N5817 T 6 3 SW1 SW2 S W3 64 1839 Switch Momentary SPST 7 1 SW4 64 1827 Switch Momentary 5mm H 8 1 J4 131 1X10S Conn Header Female Single Row 10 pins 9 1 J2 131 1X06RA Conn Header Right Angle Male 1 row of 6 pins 10 1 J3 131 1X05RA Connector Header Right Angle Male 1 row of 5 pins 11 1 J1 134 002 Connector Power 2 1mm PCB Mount 12 1 RN1 95 103 Res network 6 sip 10K 5 Res SIP Package 13 1 X1 4...

Page 9: ...PART NO DESCRIPTION 1 2 255 25511 Hardware Standoff Nylon M3 x 12 mm 2 4 255 29341 Hardware Screw Nylon M3 x 0 50 mm Thread 6mm White used for temporary assembly only 3 2 255 29346 Hardware Screw Nylon M3 x 0 50 mm Thread 16mm White 4 2 255 29347 Hardware Screw Nylon M3 x 0 50 mm Thread 20mm Black 5 2 255 876 Hardware Spacer Round 0 25 Hole Size 4 2 1 4 3 5 ...

Page 10: ...T NO DESCRIPTION 1 1 86 18111901 Front Panel Acrylic 3mm Transparent Red 2 1 86 18111902 Back Panel Acrylic 3mm Clear 3 1 86 18111903 Top Panel Acrylic 3mm Clear 4 1 86 18111904 Bottom Panel Acrylic 3mm Clear 5 1 86 18111905 Left Side Panel Acrylic 3mm Clear 6 1 86 18111906 Right Side Panel Acrylic 3mm Clear 7 1 86 18111907 Front Window Label 1 5 6 2 7 3 4 ...

Page 11: ...erations you will perform while assembling your kit A good solder connection will form an electrical connection between two parts such as a component lead and a circuit board foil A bad solder connection could prevent an otherwise well assembled kit from operating properly It is easy to make a good solder connection if you follow a few simple rules Use the right type of soldering iron A 22 to 25 w...

Page 12: ...LOCK P N CLK056 ASSEMBLY OPERATION MANUAL 10 REV 1 0 GEKCO INC 5 Step By Step Assembly 5 1 Display Circuit Board Figure 1 Display Board Top Side Completed Assembly Figure 2 Display Board Bottom Side Completed Assembly ...

Page 13: ...he bottom side facing up as shown U3 NOTCH Figure 3 Display Board Bottom Side Locate the 24 pin IC socket for U3 Place the socket on the board with the notch on the socket aligned with the notch noted on the printed circuit board PCB silkscreen Turn the board over and solder the corner pins and check to be sure the socket is firmly against the board and then solder the rest of the pins X3 24 pin D...

Page 14: ...trolytic capacitor look at it and identify the leads One lead will have either a negative mark or a positive mark near it on the side of the capacitor The aluminum electrolytic capacitor has the marking for a negative lead which may look like an oblong bar sometimes with a circle around it inside an arrow Be sure to install the positive lead in the positive marked hole C2 10 uF radial lead electro...

Page 15: ... DS3 7 segment LED display module Make sure the LEDs are oriented correctly there is a flat side on the LED housing or make sure the long lead anode is inserted in the square hole and the short lead cathode in the round hole LED3 LED Red PCB Mount LED4 LED Red PCB Mount LED5 LED Red PCB Mount LED6 LED Red PCB Mount Note LED1 and LED2 are not installed in this version of the display board Solder th...

Page 16: ...uF radial lead electrolytic aluminum capacitor Figure 8 Main Board Top View 3 Y1 Crystal HC49 16 MHz For the next step be careful to position the end with the dot or line towards the square pad and tapered outline on the circuit board After you solder the first pin make sure the pins are fully seated in their holes solder the rest of the pins to the foil RN1 10 k 103 resistor pack NOTE When you in...

Page 17: ... parts Quantity 2 of M3 x 12 mm nylon standoffs Quantity 4 of M3 x 6 mm nylon screws The display board assembled earlier The display board connector J1 Connector header male 10 pin The main board connector J4 Connector Header Female 10 pin Refer to figure 10 and 11 for the next steps Mount two M3 x 12 mm nylon standoffs with two M3 x 6 mm nylon screws on the main board as shown 2 M3x12 mm nylon st...

Page 18: ...P1 is greater than 2k ohms IC INSTALLATION NOTE You will install the following IC s on the main circuit board CAUTION Integrated circuits IC s are complex electrical devices that perform many complicated operations in a circuit These devices can be damaged during installation Read all of the following information before you install the IC s Some of the IC s you will install in the following steps ...

Page 19: ... The majority of kits that fail are due to poor solder connections Therefore you can eliminate many difficulties by carefully inspecting each connection to make sure it is soldered as described in the solder instructions section Reheat any doubtful connections 2 Check the circuit board to be sure there are no solder bridges between adjacent connections 3 Check capacitor values carefully Be sure th...

Page 20: ...l of the enclosure onto the main board assembly Make sure the switches properly align with the top piece of the enclosure Figure 14 Enclosure Back with Top Add the main board assembly with the top panel on to the screws and spacers Insert the two M3 x 12mm hex standoffs and secure to the two rear screws Mate the display board to the main board and make sure the connector in mated properly Add the ...

Page 21: ...ting holes Add the front panel and make sure all pieces are aligned properly Add two black screws and loosely tighten to secure the enclosure Congratulations you have successfully completed the assembly of the unit and now you can enjoy using a clock that you have assembled yourself ...

Page 22: ... display boards which could vary in size If may be helpful to review the block diagram and schematics while reading the circuit descriptions 11 1 Main Board Circuit Description The main circuit board has the microcontroller real time clock RTC switch inputs and connectors for the display board programming interface and the input power The microcontroller U3 is the heart of the clock This design us...

Page 23: ...o and can use the popular Arduino IDE The path for the input power for the clock is provided by connector J1 The input voltage should be 5V 5 Diode D1 is a schottky diode which provides protection of the internal circuits if the polarity of the applied voltage is incorrect Resistor network RN1 provides the 10kohm pull up resistors for the switch inputs SW1 through SW4 SW1 SW2 and SW3 provide the c...

Page 24: ...REMENT MINUTES INCREMENT SECONDS MENU MENU MENU MENU SET MENU SET MENU PLUS MENU SET MENU LOOP SELECT HOURS SELECT MINUTES SET PLUS MENU PLUS ALARM LOOP RETURN TO FUNCTION LOOP INCREMENT HOURS INCREMENT MINUTES RETURN TO FUNCTION LOOP RETURN TO FUNCTION LOOP MENU MENU MENU SET PLUS PLUS 30 SECOND TIME OUT ON ALL FUNCTIONS SET UTC HOURS INCREMENT HOURS PLUS MENU MENU SET UTC ON OFF MENU SET MENU TO...

Page 25: ...DIGITAL CLOCK MODEL CLK056 GEKCO INC Rev 1 0 23 12 2 Firmware Design Description 13 PCA Pictorial Diagrams 13 1 Main Board ...

Page 26: ...GEKCO DIGITAL CLOCK P N CLK056 ASSEMBLY OPERATION MANUAL 24 REV 1 0 GEKCO INC 13 2 Display Board Figure 15 Display Board Top Side ...

Page 27: ...DIGITAL CLOCK MODEL CLK056 GEKCO INC Rev 1 0 25 Figure 16 Display Board Bottom Side ...

Page 28: ...GEKCO DIGITAL CLOCK P N CLK056 ASSEMBLY OPERATION MANUAL 26 REV 1 0 GEKCO INC 14 Schematic Main Board ...

Page 29: ...DIGITAL CLOCK MODEL CLK056 GEKCO INC Rev 1 0 27 15 Schematic Display Board ...

Page 30: ...GEKCO DIGITAL CLOCK P N CLK056 ASSEMBLY OPERATION MANUAL 28 REV 1 0 GEKCO INC 16 Document Revision History 1 0 30 Nov 18 Initial Release ...