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Nixie Clock Type ‘Frank 3’

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Nixie Clock Type ‘Frank 3’ Assembly Instructions And User Guide Nixie Clock Type ‘Frank 3’ Software version: 5R Hardware Revision: 12 Dec 07, 7 Jan 08 Nixie Clock ‘Frank 3’ - 1 - Table of Contents 1. INTRODUCTION ................................................................3 1.1 About the clock...............................................................3 1.2 Clock features.................................................................3 1.3 Safety ...........................................................................4 2. TOOLS AND EQUIPMENT REQUIRED ............................... 5 2.1 Tools required to assemble the PCB...................................5 2.2 Materials you will need ....................................................6 2.3 Other items you will need ................................................6 3. LIST OF COMPONENTS.......................................................6 3.1 Table of components .......................................................6 3.2 Parts list ................................................................. 7 3.3 How to identify the correct components .............................8 4. ASSEMBLY OF THE PCB ......................................................9 4.1 Diodes D1-D4 .................................................................9 4.2 Diode D5 .......................................................................9 4.3 IC2 and C3.....................................................................9 4.4 IC1 and Q1 .................................................................. 10 4.5 C1, C2 and C5 .............................................................. 10 4.6 R1, R2, R3, R5, R6 ........................................................ 10 4.7 Variable resistor VR1 ..................................................... 11 4.8 MOSFET Q2 .................................................................. 11 4.9 Inductor L1 .................................................................. 12 4.10 Testing the 170V and 5V power supplies ........................ 12 4.10.1 Making up the Power Input Cable ............................... 12 4.10.2 Testing the power supplies ........................................ 14 4.11 Socket for IC3, IC4...................................................... 14 4.12 R28, C6, D6................................................................ 14 4.13 Q3-Q8, Q9-Q14, R7-R24 .............................................. 15 4.14 1mm Nixie Tube Sockets .............................................. 15 4.15 R25 ........................................................................... 15 4.16 Nixie Tubes IN-17 ....................................................... 15 4.17 SW1, SW2.................................................................. 16 4.18 Wire Link.................................................................... 16 5. FINAL TESTING OF PCB.................................................... 17 6. HOW TO OPERATE THE CLOCK ......................................... 18 7. CIRCUIT DIAGRAM .......................................................... 20 8. DIMENSIONED DRAWING ................................................ 21 Nixie Clock ‘Frank 3’ - 2 - 1. INTRODUCTION 1.1 About the clock Nixie clock type ‘Frank 3’ is a compact design with all components and tubes mounted on a single PCB. The efficient use of board space is achieved by using a multiplex design to drive the display tubes. Only a single high-voltage binary-to-decimal decoder IC (74141) is required, and each tube is switched on in sequence very quickly to give the illusion that all the tubes are actually lit. The larger tubes for hours and minutes are type IN-12 with a digit height of 18mm. The smaller tubes for the seconds are type IN-17 with a digit height of 9mm. These tubes are Russian in origin and were produced during the 1980’s, when the technology was at it’s most advanced. It is expected that the tubes will last for very many years and should not need replacing. The optional wooden case and hardware pack (rear cover, screws), supplied rough-machined, can be finished to give a very attractive clock for everyday living spaces. The quality of the final finish will reflect the time and care that is taken to finish the wood with successively finer grades of sandpaper. Alternatively, you may wish to design your own enclosure for the clock 1.2 Clock Features Nixie clock type ‘Frank 3’ has the following features: - Hours, Minutes and Seconds display - Uses the mains AC as the timebase - Selectable at power-up to work with 50Hz (Europe) or 60Hz (Americas) - Simple time setting using two buttons - 12 or 24 hour modes - Maintains time during setup mode, eg. When changing between Standard time and Daylight Savings Time - Seconds can be reset to zero to make small adjustments / precisely set time - Three display modes: Blanked / Standard change of digits / Fading digits Nixie Clock ‘Frank 3’ - 3 - 1.3 SAFETY DANGER: The clock pcb includes a switched-mode voltage booster circuit. This generates nominally 180 Volts DC, but is capable of generating up to 300 Volts before adjustment. Assembly may only be undertaken by individuals who are suitably qualified and experienced in electronics assembly, and are familiar with safe procedures for working with high voltages. If in doubt, refer to a suitably qualified engineer before proceeding. The voltages generated by this circuit can give a potentially LETHAL ELECTRIC SHOCK. DISCLAIMER: This product is supplied as a kit of parts, intended only for suitably qualified electronic engineers, who are suitably qualified and experienced in electronics assembly, and are familiar with safe procedures for working with high voltages. The supplier, his agents or associates accept no liability for any damage, injury or death arising from the use of this kit of parts. This is not a finished product, and the person assembling the kit is responsible for ensuring that the finished product complies with any applicable local regulations governing electrical equipment, eg. UL, CE, VDE. Nixie Clock ‘Frank 3’ - 4 - 2. TOOLS AND EQUIPMENT REQUIRED 2.1 Tools required to assemble the PCB The following tools will be required to assemble the PCB: - Soldering iron with a small tip (1-2 mm) - Wire cutters (TIP: A small pair of nail clippers works very well for this function) - Wire strippers (TIP: A small pair of scissors is quite suitable) - Multimeter - Small flat screwdriver for adjusting the high voltage supply 2.2 Materials you will need Solder – lead / tin solder is preferred. Lead – free solder, as now required to be used in commercial products in Europe, has a much higher melting point and can be very hard to work with. Desoldering wick (braid) can be useful if you accidentally create solder bridges between adjacent solder joints. 2.3 Other items you will need The clock kit does not include a power adapter. This is because the kit is sold to many countries around the world, each with very different household mains outlet socket types. It is more efficient for the user to buy a suitable adapter locally. This saves shipping a heavy adapter with the kit, and also the extra costs of managing stocks of many varied power adapters. The type of power adapter can be obtained at very low cost. The following type of adapter should be obtained and used with the kit: Mains AC to AC adapter (This is important, as the AC signal is needed for the timebase) Output 9-12V AC Minimum power output capability of 250 mA Output plug: 2.1mm pin A suitable adapter is shown in figure 1 below: Figure 1 Nixie Clock ‘Frank 3’ - 5 - 3. LIST OF COMPONENTS 3.1 Table of components (In sequence) Circuit Designation Part Description Resistors R1 33K, ¼ Watt R2 10K, ¼ Watt R3 1K, ¼ Watt R4 Not Installed R5 470R, ¼ Watt R6 220K, ¼ Watt R7-R12 390K, ¼ Watt R13-R22 5.6K, ¼ Watt R23, R24 10K, ¼ Watt R25 390K, ¼ Watt R26 Not Installed R27 Not Installed R28 33K, ¼ Watt Capacitors C1 470uF, 16-25V, Electrolytic C2 100uF, 16-25V, Electrolytic C3 2.2nF ceramic or polyester C4 Not Installed C5 1uF, 250V, Electrolytic C6 22nF, ceramic or polyester Transistors Q1 MPSA42 NPN Q2 STP7NK30Z N-Channel MOSFET Q3-Q8 MPSA92 PNP Q9-Q14 MPSA42 NPN Diodes D1-D4 1N4001 D5 1N4936 fast recovery diode D6 5.6V Zener Diode D7 Not Installed Integrated Circuits IC1 78L05 5V voltage regulator IC2 NE555 Timer IC IC3 PIC16F627A 8 bit Microcontroller IC4 74141 / K155N Nixie driver Miscellaneous L1 100uH – 220uH Inductor NE1, NE2 4mm wire ended neon lamp NX1-NX4 IN-12 Nixie tube NX5, NX6 IN-17 Nixie tube SW1, SW2 Miniature push button VR1 1K Potentiometer PCB ‘Frank 3’ PCB IC Socket 18 Way IC Socket for IC3 CONN 2.1mm Power socket Cable ~60mm two way cable SKT1-44 1mm Harwin solder-in socket Nixie Clock ‘Frank 3’ - 6 - 3.2 Parts list / Packing sheet Part Description Quantity Resistors 33K, ¼ Watt 2 10K, ¼ Watt 3 1K, ¼ Watt 1 470R, ¼ Watt 1 220K, ¼ Watt 1 390K, ¼ Watt 7 5.6K, ¼ Watt 10 Capacitors 470uF, 16-25V, Electrolytic 1 100uF, 16-25V, Electrolytic 1 2.2nF ceramic or polyester 1 1uF, 250V, Electrolytic 1 22nF, ceramic or polyester 1 Transistors STP7NK30Z N-Channel MOSFET 1 MPSA92 PNP 6 MPSA42 NPN 7 Diodes 1N4001 4 1N4936 fast recovery diode 1 5.6V Zener Diode 1 Integrated Circuits 78L05 5V voltage regulator 1 NE555 Timer IC 1 PIC16F627A 8 bit Microcontroller 1 74141 / K155N Nixie driver 1 Miscellaneous 100uH – 220uH Inductor 1 4mm wire ended neon lamp 2 IN-12 Nixie tube 4 IN-17 Nixie tube 2 Miniature push button 2 1K Potentiometer 1 ‘Frank 3’ PCB 1 IC Socket, 18 way DIL 1 2.1mm Power Connector 1 Cable – 60mm piece 1 1mm Harwin solder-in
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