KABTRONICS World Clock 2, Operating And Assembly Manual

Page 1: ...World Clock 2 Operating and Assembly Manual ...

Page 2: ...TRUCTIONS 8 MASTER BOARD 18 DISPLAY BOARD 23 TESTING CONTROLLER AND DISPLAY SLICES 25 CLOCK CONFIGURATION 26 CLOCK ACCURACY 28 MULTI BOARD CLOCKS 28 CASES 28 PARTS IDENTIFICATION 30 THEORY OF OPERATION 37 IN CASE OF DIFFICULTY 39 SPECIFICATIONS 40 CIRCUIT BOARD VIEWS 41 Copyright March 31 2015 by KABtronics ...

Page 3: ...K A B T R O N I C S World Clock Kit Page 3 3 3 3 Document version 1 20 for use with PC board version 3 ...

Page 4: ... Slice This clock is made of slices one controller slice zero or more display slices Each slice shows two lines of time Display Slice This manual first guides the assembly of the slices followed by operating the clock There is a section describing the parts if you are unfamiliar with electronic parts and a section describing the underlying design of the clock ...

Page 5: ...ohm 1 4 Watt Cfilm 24 Tran NPN 2N3904 3 Diode Schottky 1N5818 1 Xtal 8M 1 IC Analog Volt Det S 808 TO 92 1 SKT IC DIP8 3 1 SKT IC DIP28 3 3 Switch Push RtAng PC board TH mount 3 CAP BLACK 3 Cap 10uF 16V Tantalum 1 JACK 2 5mm Right Angle 1 Supply 5Volt 2Amp 1 PCB World 2 DISPLAY SLICE PARTS LIST Qty Description 1 IC uProc PIC18LF2510 DIP 28 12 IC SAA1064 7segDvr 20 LED 16 segment Red LTP 587HR 8 LE...

Page 6: ...f solder left on the tip helps conduct heat to the lead and the pad Insert the component leads and press the component flat against the PC Board Slightly spread the leads to hold it in place when you flip the board over to expose the back side with the component lead facing up Make good contact between the iron the lead and the pad on the board so the lead and the pad both heat up enough to melt t...

Page 7: ...fter inspecting the solder joint clip off the excess lead using the diagonal cutter Cut at the top of the solder joint don t dig into the solder joint Unsoldering A supply of de soldering braid is supplied with the kit If you find the need to remove a component use the de solder braid by pulling out a few inches and pressing the braid against the lead and the pad using the iron You will see the so...

Page 8: ...nstructions You will need the following tools to build your clock Soldering Iron meant for electrical work Small Diagonal Wire Cutter One side of the PC board has white paint markings shapes and reference designators That marked side is the component side upon which all the components will be placed ...

Page 9: ...N I C S A S S E M B L Y I N S T R U C T I O N S World Clock Kit Page 9 9 9 9 Display Drivers Load 16 SAA1064 display drivers U5 U16 The mark or notch on the SAA1064 should match the notch on the silkscreen Displays ...

Page 10: ...he 20 16 segment displays with the decimal point towards the bottom Be quick about soldering these displays overheating can damage them Clip the leads off after soldering Load the eight 7 segment displays Once again the decimal point goes on the bottom and once again be quick with the soldering iron ...

Page 11: ...K A B T R O N I C S A S S E M B L Y I N S T R U C T I O N S World Clock Kit Page 11 11 11 11 0 0027uF Capacitors Load the twelve 0 0027 uF capacitors ...

Page 12: ...N I C S A S S E M B L Y I N S T R U C T I O N S World Clock Kit Page 12 12 12 12 0 22uF Capacitors Load the thirteen 0 22 uF capacitors LEDs Load the eight LEDs The shorter lead is closer to the bottom of the board ...

Page 13: ...S E M B L Y I N S T R U C T I O N S World Clock Kit Page 13 13 13 13 In order to make them level with the 7 segment displays and straight solder only one of the leads Then you can adjust the LED and then solder the other lead ...

Page 14: ... T R O N I C S A S S E M B L Y I N S T R U C T I O N S World Clock Kit Page 14 14 14 14 Transistors Load the twenty four NPN transistors Note that the two on the right are rotated differently than the others ...

Page 15: ...C T I O N S World Clock Kit Page 15 15 15 15 10uF Capacitors load the three 10uF capacitors They may have a small sign near the lead or they may be marked with a line as below The symbol on the board has a small sign nearer the hole for the lead lead ...

Page 16: ...A S S E M B L Y I N S T R U C T I O N S World Clock Kit Page 16 16 16 16 Sockets Load the IC sockets Make sure to orient the sockets to match the outlines on the board NOTE the display board does not have the 8 pin socket ...

Page 17: ...C S A S S E M B L Y I N S T R U C T I O N S World Clock Kit Page 17 17 17 17 Voltage Sensor and Resistors Load R4 10K R6 10K R2 1K SKIP R2 for display board not needed Load U17 voltage sensor it looks like a transistor ...

Page 18: ...Kit Page 18 18 18 18 Master Board If you are building a master board continue on For a display board skip forward to the Display Board build instructions Crystal 22pF Caps Load the crystal and the two 22 pF capacitors These are non polarizied and can go in either direction ...

Page 19: ...K A B T R O N I C S A S S E M B L Y I N S T R U C T I O N S World Clock Kit Page 19 19 19 19 ...

Page 20: ...B T R O N I C S A S S E M B L Y I N S T R U C T I O N S World Clock Kit Page 20 20 20 20 Power Parts Load three diodes the 100 ohm resistor R1 and the disc capacitor just as shown in the picture and diagram ...

Page 21: ...N I C S A S S E M B L Y I N S T R U C T I O N S World Clock Kit Page 21 21 21 21 Switches Load the three switches Try to make them straight Solder only one pin straighten the LEDs and then solder the remaining pins ...

Page 22: ...sing multiple boards you may want to mount the socket on the edge or bottom of the bottom display board in the group The location to use depends upon your usage of the board Don t place the jack on the bottom of any board that will be connecting to a lower board Keep in mind that in normal usage you will only use the switches once a year to enter new daylight savings dates so having it near the sw...

Page 23: ...lay board comes with two 20 pin connectors One is for the board above it and on is for the display board Load the female block connector in the lower position of the controller board Load the male connector on the top of the display board If this display board will be connecting to another display board below load the female connector from the 2nd slice in the lower position of the 1st display boa...

Page 24: ...K A B T R O N I C S A S S E M B L Y I N S T R U C T I O N S World Clock Kit Page 24 24 24 24 ...

Page 25: ...d Clock Kit Page 25 25 25 25 You are Done Testing controller and display slices The controller slice can be tested after building and before configuration power it up and use the menu buttons to advance to test When using the test menu the clock response is sluggish ...

Page 26: ...played on the controller card If you have displays cards chained below the controller the remaining locations are displayed in groups of two for each additional display board up to location 14 Location 0 and 15 are not mapped onto display cards These two locations can be used as intermediate storage locations to help when configuring the clock They can also be used with display redirection discuss...

Page 27: ...r example to get to the TIME SETTING MENU press the MODE and the display will show SET TIME press SELECT to see SET YEAR Now UP and DOWN adjust the numeric value and MODE moves to the next time parameter This menu will cycle to RUN after Set MINUTE NOTE Set the time to UTC Universal Coordinated Time which can be found using the internet Each location holds the time offset the daylight savings offs...

Page 28: ...ose 15 seconds the clock is 24 8 PPM slow so set PPM to 25 15 seconds number of seconds in 7 days x 1 million 24 8 PPM If you were 4 seconds fast PPM 6 6 PPM fast so set PPM to 7 Multi board clocks Multi board clocks are simply a chain of display boards connected below a controller board There is a setting of how many locations to display from 1 to 14 The main issue is the power supply Each board ...

Page 29: ...K A B T R O N I C S A S S E M B L Y I N S T R U C T I O N S World Clock Kit Page 29 29 29 29 ...

Page 30: ...30 30 30 Parts Identification Resistors Resistors can be identified by the color bands as shown in the adjacent chart These parts can be placed in either direction on the board they are not polarized Diodes This is a polarized part the stripe needs to match the stripe on the PC board ...

Page 31: ...d Circuits These come in 8 pin 24 pin and 28 pin versions The 24 pin IC is soldered directly to the board the 8 and 18 pin ICs are placed in sockets mainly because they are reprogrammable parts and you may want to update the software IC sockets These come in 8 pin and 28 pin versions Be sure to mount this part with the marking for pin one matching the PC board ...

Page 32: ...Kit Page 32 32 32 32 LED Displays 16 segment LED display 7 segment LED display 7 segment display on the right and a single LED on the left The short lead goes into the square hole on the board Try to be quick when soldering these displays they are sensitive to overheating ...

Page 33: ... The 22 pF capacitor look similar to this don t get them confused Both this and the 0 0027 cap are non polarized mount it either way 1 Farad cap This part needs to be installed carefully it is polarized Look carefully at the picture in the mounting instructions The metal strap is negative side of the capacitor ...

Page 34: ...E N T I F I C A T I O N World Clock Kit Page 34 34 34 34 10 microfarad cap Negative side Positive side The long line identifies the positive side which need to go into the hole near the sign Switches Power Socket ICs Integrated Circuits ...

Page 35: ...This kit has 8 pin 24 pin and 28 pin ICs Header and Connector Connector Header These are a pair of mating 20 pin right angle connectors The header goes in the top location and the connector goes into the lower location Crystal This crystal can be loaded in either direction it is not polarized ...

Page 36: ... A R T S I D E N T I F I C A T I O N World Clock Kit Page 36 36 36 36 Voltage Detector This voltage detector looks just like a transistor b ut is an Integrated Circuit instead Load it to match the outline on the silkscreen ...

Page 37: ...t drivers This clock is built from function blocks Processor o Holds the program that controls the clock Watches the 5 volt power and when the 5 volts is missing it switches to a low power mode attempt to keep running until the power returns Power backup o Has a 1 Farad capacitor that powers the processor only when the 5 volt supply is lost Uses diode switching to select which supply to use ...

Page 38: ...nd displays it If a line number is greater than 2 it sends the data out the serial port with the line number Slice operation The display microprocessor accepts line information from slices above and displays lines with the number of 0 or 1 Larger line numbers will cause the line information to be modified by decrementing the line number by two the data is repacked and sent to the slice below Power...

Page 39: ...onent loaded Component loaded backwards Bad solder joint causing open or short to adjacent pad A clipped off lead has stuck to the back of the board and is shorting out the circuit The board is resting on something conductive shorting out the circuit A component is bad because o it was over heated when soldered medium chance o came that way with the kit low chance o was damaged by static electrici...

Page 40: ...arts clearance Weight About 10 oz not including power brick Power consumption About 3 7 watts 0 75 amps 5 volts DC brightness level 3 Temperature limits Designed for room temperature operation 60 80 F Warrantee There is no warrantee of any kind KABtronics wants you to succeed and be happy with your clock so don t hesitate to email customerservice transistorclock com with questions if you are havin...

Page 41: ...K A B T R O N I C S P A R T S I D E N T I F I C A T I O N World Clock Kit Page 41 41 41 41 Circuit Board Views SILK SCREEN ...

Page 42: ...K A B T R O N I C S P A R T S I D E N T I F I C A T I O N World Clock Kit Page 42 42 42 42 Top Copper ...

Page 43: ...K A B T R O N I C S P A R T S I D E N T I F I C A T I O N World Clock Kit Page 43 43 43 43 Bottom Copper ...

Page 44: ...K A B T R O N I C S P A R T S I D E N T I F I C A T I O N World Clock Kit Page 44 44 44 44 Schematic ...

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