ANGRY ELECTRONICS WordClock 4-6 User manual

WordClock-4 Assembly Guide 05/15/21 Version 0.8
Page 1
WordClock 4-6 and WordClock 4-8 Assembly Guide
6 and 8 Tube B7971 Version
Contents
Introduction 2
Assembly 2
Case 2
Step 1 – Build the Main Board 3
Step 2 – Final Assembly 5
Bill of Materials 6
Schematic 8
Warranty Terms and Conditions 10

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Introduction
WordClock-4 assembly should be attempted only by experienced builders. Although assembly
is straightforward and not difficult for experienced kit builders, there are several surface mount
parts that must be carefully soldered to the boards. The kit may be returned for a full refund
less shipping within 30 days of purchase, only if assembly has not been attempted.
SIX OR EIGHT B7971 TUBES ARE REQUIRED AND NOT INCLUDED IN THIS KIT.
Assembly
WARNINGS!
DRILL HOLES IN THE CASE BASE FIRST. USE THE CIRCUIT BOARD AS A TEMPLATE.
DO NOT SOLDER THE MICROCONTROLLER DIRECTLY TO THE BOARD, USE
HEADERS.
USE A GOOD QUALITY, UL LISTED, 12V POWER SUPPLY.
Case
If you purchased the optional acrylic case, this would be a good time to mark and drill the holes
in the base. It is easiest to use an unpopulated circuit board for this purpose. The board
dimensions for the six-digit clock are 380mm wide by 85mm deep. The dimensions of the eight-
digit version are 510mm wide x 85mm deep.

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Step 1 – Build the Main Board (6-Tube Board Shown For Reference)
• Install the female pin sockets on top of the board. Use masking tape to hold them in
place while soldering on the bottom of the board.
• Cut the single row 40 pin female header into two, 17 pin pieces. Install at the U4 location.
Install two, 2x6 female headers at the HVPS1 and HVPS2 locations.
DO NOT solder the microcontroller to the board!
• Build the 5v supply on the main board. Install J1, F1, C1, C2, C3, D1, D2, L1, and U1.
Note that C1, C2, D1, and D2 must be installed in the direction noted on the board.
• Connect a 12V-18V power supply with a center positive, 2.1mm connector to J1, and
check the test point for 5V. Do not continue assembly if 5V is not present at the test point.
• Build the high voltage supplies. Install R1, R2, R6, R7, R33, R34, NE8, and NE8.
Connect a temporary jumper between ENABLE and +5V. This will turn on the high
voltage power supplies. Do not install the microcontroller while the jumper is in
place or while testing the power supplies, or the microcontroller will be damaged!

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• Install one or two TaylorEdge 1363 high voltage power supplies with the coils facing the
word, “COIL” on the board. If only one power supply is used, connect a jumper between
HVJP1 and HVJP2.
• There is no load balancing facility available so do not connect this jumper if two
power supplies are used.
Connect the 12V power supply. Both neon bulbs should now be lit. Check one or both
+170V test points for approximately +170V.
If the voltages check out and the neon bulbs are lit, remove the power supplies and the
ENABLE jumper.
• Install the components on the bottom of the board, starting with the surface mount
resistors. Note that each “00” series is the same value, for ease of assembly.
• Install the surface capacitors, followed by the ICs. The line or dot on one side of each
chip must be installed toward the cutout on one side of the silkscreened pattern. The
best way to install a surface mount chip is to add a very small amount of solder to one
of the corner pads on the board. Then quickly and carefully solder the corresponding pin
to the pad. Check the alignment of all pins and if correct, solder the opposite corner pin.
Check the alignment again, then solder the remaining pins quickly and carefully. Always
use a magnifier to check for solder bridges and bad solder joints. The HV5530s are very
difficult to solder successfully and must be checked with magnification to ensure that
each pin is soldered, and that there are no solder bridges. Use solder braid to easily
remove solder bridges.
• Install the SD card connector next. Be sure to solder all leads to the board. Solder quickly
and carefully. The plastic chassis can easily be damaged by too much heat. Several pins
on one side of the connector are very close to the grounded case. They do not need to
be soldered. Then install J3, the GPS connector.
• Install all of the remaining parts on the top of the board. Note that the APA102 RGB LEDs
must be installed with the cutout facing the dot on the board.
• The ambient light sensor, Q2, should be installed about 10mm above the board. The
shorter lead goes toward the back of the board.

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Step 2 – Final Assembly
• Carefully install the tubes, and reinstall the power supplies. Make absolutely sure that
the ENABLE jumper has been removed.
• Install the microcontroller board, correctly orienting the USB connector and antenna, with
the markings on the board. Install the SD Card.
• Install six, 10mm standoffs into the holes on the bottom of the main board, using six
screws (or 8 for the 8-tube version)
This completes WordClock-4 assembly. Refer to the User Manual for setup and operation
instructions.

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Bill of Materials
Reference
Qty
Part
Value
Note
C1-C2
2
Capacitor
330uf 25v-50v
Electrolytic
C3-C6, C8, C13
6/7
Capacitor
100nf
Surface mount – C14 for 8 tube
C7, C9-C12
5
Capacitor
100nf
Through hole
D1
1
Diode
1N4007
D2, D5
2
Diode
1N5819
Schottky
F1
1
Poly Fuse
0.5A – 1A
J1
1
Power Jack
2.1mm power jack
J2
1
GPS Jack
3.5mm SMD SJ-3523-SMT-TR
J3
1
SD Card
Connector
DM1AA-SF-PEJ SD card jack
J4
1
Header
Not Used
L1
1
Inductor
100uh
LED1-LED12
12/16
RGB LED
APA102
PZ1
1
Buzzer
Buzzer
Q2
1
Sensor
TEPT4400
Light sensor
R1
1
Resistor
7.5k ¼ watt
8 Tube Board only
R3, R4, R7,
R19, R20
5
Resistor
10k ¼ watt
Brown-black-orange-gold or
brown-black black-red-gold
R2, R33
2
Resistor
270k ¼ watt
Red-violet-yellow-gold or red-
violet-black-orange-gold
R5, R8
2
Resistor
330R
8 Tube Board only
R6, R34
2
Resistor
47k ¼ watt
Yellow-violet-orange-gold or
yellow-violet-black-red-gold
R18
1
Resistor
120k ¼ watt
brown-red-yellow-gold or brown-
red-black-orange-gold

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R21, R24
2
Resistor
4.7k ¼ watt
Yellow-violet-red-gold or yellow-
violet-black-brown-gold
R100 Series
12/16
Resistor
22k
223 Surface mount 1210/1206
R200 Series
24/32
Resistor
24k
243 Surface mount 1210/1206
R300 Series
42/56
Resistor
27k
273 Surface mount 1210/1206
R400 Series
12/16
Resistor
33k
333 Surface mount 1210/1206
R500 Series
4
Resistor
270k
274 Surface mount 1210/1206 (6
Digit only)
SW1-SW2
2
Button
90 Degree pushbutton
U1
1
IC
CD4504
U2
1
IC
LM2576
U3
1
IC
74HC14D
8 Digit clock only
U4
1
IC
74AHC125D
6 Digit clock only
U5
1
Microcontroller
ESP32-PICO-
KIT
Programmed with WordClock
firmware
1
Header Strip
Cut into two to mount U5
HV1-HV3
3
IC
HV5530PGG-G
HV4
1
IC
HV5530PGG-G
8 Digit clock only
6/8
Screw
M3 8mm
6/8
Standoff
10mm
1
SD Card
Programmed with WordClock
languages database
1
Main Board
102
Socket pins
6 Digit clock only
136
Socket pins
8 Digit clock only
1/2
Female Header
2 x 6
Power supply connectors

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HVPS1, HVPS2
2
Power supply
TaylorEdge
1363 low noise
One may be used for 6-digit
clocks, but two are
recommended. Two are required
for 8-digit clocks.
NE1-
NE4,NE7,NE8
6
Neon Bulb
6 Digit clock only
2
Brass tube
1.5mm x 90mm
6 Digit clock only
2
Brass tube
1.5mm x 50mm
6 Digit clock only
6/8
Acrylic diffusers

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Schematic

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Warranty Terms and Conditions
This software and hardware product is Copyright (C) 2019 by Mitchell Feig. It is exclusively
distributed by StocksClocks LLC. All Rights Reserved. StocksClocks warrants that for a period
of 90 days following delivery, kit parts will (a) perform in accordance with published
specifications, and (b) will be free from defects in materials and workmanship. In the event a kit
part does not meet this warranty, subject to the conditions set forth in these terms and
conditions, StocksClocks sole obligation will be, at its election, to repair or replace the kit part
in question. We may require return of the part for examination and replacement. Replacement
will be completed at the sole discretion of StocksClocks, after examining the returned part.
Correct assembly is the responsibility of the builder.
StocksClocks MAKES NO OTHER WARRANTIES, EXPRESS OR IMPLIED, AND ALL
IMPLIED WARRANTIES OF MERCHANTABILITY, NON-INFRINGEMENT, AND FITNESS
FOR A PARTICULAR PURPOSE ARE HEREBY DISCLAIMED. IN NO EVENT WILL
Stocksclocks BE LIABLE FOR PUNITIVE, SPECIAL OR CONSEQUENTIAL DAMAGES, OR
FOR AN AMOUNT IN EXCESS OF THE PURCHASE PRICE OF THE DEFECTIVE
Stocksclocks PART OR PRODUCT.