Assembly Manual „Leon“ USB powered Nixie Clocks · parts runs hot. If everything is allright we will do follwing some voltage checkings: Please check the voltages on the PIC’s

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 !


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


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.


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


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

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Title

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Date: Sheet of

Main Board with IN-2 Laura Tube Board 10/2012

USB powered Nixie Clock

A4

1 1Tuesday, October 09, 2012

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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

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TR122k

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H1H1

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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

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LED3LED3RGB

A

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LED B 27LED G 26LED R 25

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HV PWM13LED DST 14

LED ALARM 15

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Title


Date: Sheet of

For USB Nixie Clock Main Board 0

Leon Tube Board

1 1Saturday, February 23, 2013

Title


Date: Sheet of


Leon Tube Board


Title


Date: Sheet of


Leon Tube Board


RN1...6 = 3 x 1k Array

H4ST12CH4ST12C

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N7N7

N20N20

RN4ARN4A

N10N10

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LED2LED2RGB

A

R1

510k

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N16N16

RN2BRN2B

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N3N3

H8H8

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A

0987654321

N13N13

H5ST12CH5ST12C

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0987654321

RN1BRN1B

RN2CRN2C

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NLRNLR

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H1ST12CH1ST12C

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N14N14

N8N8

RN3ARN3A

H6ST12CH6ST12C

A

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RN4CRN4C

RN5BRN5B

RN1CRN1C

NA4NA4

N19N19

LED5LED5RGB

A

LED1LED1RGB

A

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RN5ARN5A

H2ST12CH2ST12C

A

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N4N4

RN3BRN3B

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RN5CRN5C

N9N9

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N18N18

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LED4LED4RGB

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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

Documents

Assembly Manual „Leon“ USB powered Nixie Clocks · parts runs hot. If everything is allright we will do follwing some voltage checkings: Please check the voltages on the PIC’s