KABTRONICS World Clock 2 Product guide

World Clock 2
Operating and
Assembly Manual

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Table of Contents
INTRODUCTION ..................................................................................................4
SOLDERING ........................................................................................................6
ASSEMBLY INSTRUCTIONS..............................................................................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

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Document version 1.20 or use with PC board version 3

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Introduction
This is a kit to build a clock displaying time or multiple locations.
Controller Slice
This clock is made o slices, one controller slice, zero or more display slices. Each slice shows two
lines o time.
Display Slice
This manual irst guides the assembly o the slices, ollowed by operating the clock. There is a
section describing the parts i you are un amiliar with electronic parts, and a section describing the
underlying design o the clock.

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Gently unpack the contents o the box using the proper parts list.
CONTROLLER SLICE PARTS LIST
Qty Description
1 IC,uProc PIC18F2450, DIP-28
1 IC,Prom, Serial, 1Mbit, DIP8
12 IC, SAA1064, 7segDvr
20 LED, 16-segment, Red, LTP-587HR
8 LED, 7-segment, Red, LDS-A414RI
8 LED, Red, 3MM
2 Cap, 22pF, Ceramic
13 Cap, .22uF, Ceramic
12 Cap, 0.0027uF Polyfilm
1 Cap, 1F, coin
1 Res, 100 ohm, 1/4 Watt, Cfilm
1 Res, 1K ohm, 1/4 Watt, Cfilm
2 Res, 10K 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 LED, 7-segment, Red, LDS-A414RI
8 LED, Red, 3MM
13 Cap, .22uF, Ceramic
12 Cap, 0.0027uF Polyfilm
1 Res, 10K ohm, 1/4 Watt, Cfilm
24 Tran, NPN, 2N3904
1 Diode, Schottky, 1N5818
1 SKT, IC, DIP28, .3
3 Cap, 10uF,16V Tantalum
1 PCB, World 2
1 20 pin rt angle dual row header
1 20 pin rt angle dual row socket

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Soldering
This manual can’t teach the art o soldering, but here are the basics. Remember, you need to
make over 700 GOOD solder joints or each slice; each bad joint will be an adventure in
troubleshooting.
Wet the tip o the iron with a bit o solder and wipe o the excess solder on the wet sponge
occasionally, or when you notice the joint is not heating properly. The small amount o solder le t
on the tip helps conduct heat to the lead and the pad.
Insert the component leads and press the component lat against the PC Board. Slightly spread
the leads to hold it in place when you lip the board over to expose the back side with the
component lead acing 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 the solder.
•It should take rom 0.5 to 1 second or the joint to become hot enough to melt the
solder.
•Don’t overheat the joint, as soon as the solder melts and wicks into the joint remove the
iron and hold still or a ew seconds until the joint reezes.

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A good solder joint will orm a shiny curved sur ace bonding the lead and the pad on the PC
board. I the lead wasn’t heated enough to melt the solder, the solder will wick in to the pad, but
will not adhere to the lead. You may notice a dark line around the lead where the solder dives
down through the hole.
A similar bad joint orms when the pad wasn’t heated enough to melt the solder. A cold solder
joint can o ten be ixed by reheating the joint; sometime a little more solder will be needed.
More detailed instructions can be ound on the internet with a little searching on the topic o
soldering.
A ter inspecting the solder joint, clip o the excess lead using the diagonal cutter. Cut at the top
o the solder joint; don’t dig into the solder joint.
Unsoldering
A supply o de-soldering braid is supplied with the kit. I you ind the need to remove a
component, use the de-solder braid by pulling out a ew inches and pressing the braid against the
lead and the pad using the iron. You will see the solder melt and spread into the wick leaving very
little solder le t in the pad.
Sometimes it helps to clip the lead o the component so you can deal with each lead separately.
Optional Clean-up
The clear sticky rosin le t around the solder site can be cleaned up with alcohol (not rubbing
alcohol) and a toothbrush, but be sure to let the board dry be ore expecting the board to operate
properly. This cleanup is optional; the clock will run ine without cleaning the rosin.

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Assembly Instructions
You will need the ollowing tools to build your clock.
•Soldering Iron meant or electrical work
•Small Diagonal Wire Cutter
One side o the PC board has white paint markings, shapes, and re erence designators. That
marked side is the component side, upon which all the components will be placed.

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isplay rivers
( ) Load 16 SAA1064 display drivers, U5-U16
The mark or notch on the SAA1064 should match the notch on the silkscreen.
isplays

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( ) Load the 20 16-segment displays with the decimal point towards the bottom.
Be quick about soldering these displays, overheating can damage them.
Clip the leads o a ter 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.

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0.0027uF Capacitors
( ) Load the twelve 0.0027 uF capacitors

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0.22uF Capacitors
( ) Load the thirteen 0.22 uF capacitors
LE s
( ) Load the eight LEDs. The shorter lead is closer to the bottom o the board.

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In order to make them level with the 7 segment displays and straight, solder only one o the leads.
Then you can adjust the LED and then solder the other lead.

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Transistors
( ) Load the twenty our NPN transistors. Note that the two on the right are rotated di erently
than the others.

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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 or the
+ lead.
+ lead

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Sockets
( ) Load the IC sockets. Make sure to orient the sockets to match the outlines on the board.
NOT : the display board does not have the 8 pin socket.

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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.

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Master Board
I you are building a master board, continue on. For a display board, skip orward 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.

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Power Parts
( ) Load three diodes, the 100 ohm resistor (R1) and the disc capacitor, just as shown in the
picture and diagram.