Steps to solder components in order for OSC 4.4 ____________________________________________ Please look the board over carefully and read the instructions and parts list to familiarize yourself with the assembly procedure before you begin. Please also familiarize yourself with transistor orientation: looking at the front (flat side), the three leads are, left to right: emitter, base, collector. All the transistors except Q11 are facing the same way on the board, with all the emitters closer to the IC’s. A diode has a + and - side, and IC's are marked on one end with a small indented "notch". The IC sockets are also notched. Electrolytic (cylindrical shape) capacitors have a + & - side . Solder all components on the bottom of the board, and insert the wires through holes & solder to bottom of board. Part 1 : High Voltage supply D1 - 1N4007 diode NOTE ORIENTATION R1 - 10 ohm , 3 W resistor ( brown black black ) D3 - 1N4007 diode NOTE ORIENTATION C1 - 4.7 uF , 450 V capacitor , NOTE ORIENTATION + - C4 - 4.7 uF , 450 V capacitor , NOTE ORIENTATION + - P2 - 1M ohm potentiometer (105), DON’T SOLDER WIPER YET P1 - 1M ohm potentiometer , DON’T SOLDER WIPER YET P3 - (top adjust) - 50Kohm (503) or 47Kohm (473) potentiometer. This is the same physical size as P1 & P2 R3 - 470K ohm, ½ W ( yellow purple yellow ) resistor Neon bulb (HV indicator) R37 - 10M ohm resistor ( brown black blue ) F1 - fuse or fuse holder & bus fuse. 4 pin jumper - only necessary to switch between 120VAC (U.S.) and 240VAC (some other countries) - If this is not necessary, you may solder a small jumper to the appropriate holes (120 or 240, marked) to make a permanent connection. Solder 8” of ~18 gauge wire with black insulation to Fuse input marked "HOT" (left side, end of Fuse closer to X1). Solder 8” of ~18 gauge wire with white insulation to NEUTRAL Transformer - Primary (1,2,3,4) side is next to fuse, secondaries (5,6,7,8) should line up w/ the holes next to the edge insert a temporary jumper (do not solder) into the lower left holes of the relay like this > (Please also see Jumper.jpg) _______ |oo oo | | | |->|oo oo | | |o o | | |o o | |->|ooo oo | |_______| Connect black wire to an AC cord hot and white wire to neutral, plug into wall outlet & test for HV Neon light should be on . Test for ~300 VDC at C6 - and R8 + , with C6 negative & R8 positive Test for ~300VDC at G (next to neon) , and C6 -, with G negative & C6 - positive If this step checks ok, disconnect the power cord & proceed to Part 2. If you are adding the battery backup option, do the following first: Relay2 - the coil goes toward C1 & C4 78L05 - 100ma 5VDC regulator R102 - 10K ohm resistor D223 - 1N4001 diode 3mm (small)LED - note orientation 9VDC IN - leads of 9V battery connector, note + & - (it may be helpful to leave this off until after the build is done) Part 2 : Low voltage supply & wave shaper, relay control If you are adding the gps module (if included), you may now solder the five pin socket behind Relay2, with the holes facing up. If you are adding your own gps module, you may want to use individual connecting wires, depending on the orientation of your gps module connecting points. S3 - tactile pushbutton switch ( toggle display on / off ) Relay - ORIENT CORRECTLY - it only fits correctly one way Rfilament - (next to S3) - this will be determined by the type of CRT used. Generally, 4.7 ohm, 3 watt works for many CRTs, however, for some types a different value may be used, i.e., some European types like DG7-6 may need a 10 ohm, 3 watt. When you first connect your CRT and power it on, you should read the voltage across the filaments (heaters) and determine if this falls within the specs for your CRT type. If the voltage is too high, use a higher value resistance for Rfilament to lower CRT filament voltage. This can be different depending on the individual crt, some experimenting may be necessary to find the optimal value, but in most cases it's okay to start by using the 4.7 ohm 3 watt resistor included. R38 - 2.2 K ohm , ¼ watt ( red red red ) Q7 - 2N3904 NPN transistor ORIENT correctly - emitter should be next to Q7 R33 - 10 K ohm , ¼ W , ( brown black orange ) B1 - full wave rectifier bridge NOTE ORIENTATION ( it has - & + ) R14 - 100K ohm , ¼ W ( brown black yellow ) C6 - 1,000 uF, 16 V+ cap NOTE ORIENTATION R29 - 1K ohm, ¼ W D56 - 1N4001 diode NOTE ORIENTATION R27 - 10 K ohm, ¼ W ( brown black orange ) Q8 - 2N3904 transistor , collector should be at Q8 D9 - 1N4001 diode NOTE ORIENTATION P6 (side adjust) - 50K ohm side adjust potentiometer (x centering) These don’t go all the way through the holes, ok to solder on top of board P7 (side adjust) - 50K ohm pot (y center) C22 - .01 uF (103) cap C10 - 100 uF, 10 V cap NOTE ORIENTATION. If installing BB option, use the 1,000uF 6.3 volt cap instead R26 - 470 ohm , ¼ W or 10K for less brightness 5mm (large) LED - NOTE ORIENTATION, long lead is anode ( + ) 7805 - 5V regulator NOTE ORIENTATION When it’s plugged in, the LED should light. Test for low voltage at C44 (+5V), right side should be negative, left side 5V positive. Test the relay control by carefully touching a jumper wire to V1 and the positive side (left side) of C44. The relay will click and the neon bulb should light . If this checks ok, go to part 3. If you got this far with it, congrats, you now have a high voltage supply, low voltage supply, wave shaping circuit and relay control circuit. The rest of the build should be easy : ) . Part 3 Q11 - MPSA92 (or KSP92) PNP transistor NOTE : This is the only transistor on the board that the flat side faces opposite of the rest (the collector is closer to the IC’s) R36 - 47K ohm resistor (yellow purple orange) R35 - 10 K ohm resistor (brown black orange) Q10 - MPSA44 (or ksp44) NPN transistor Q1 - MPSA44 NPN transistor R99 - For a DG7-32 crt- 330K ohm resistor ( orange orange yellow ) , For a 2BP1 crt - 220K ohm ( red red yellow ) R4 - For a DG7-32 crt- 330K ohm resistor ( orange orange yellow ) , For a 2BP1 crt - 220K ohm ( red red yellow ) R6 - 180 K ohm resistor (brown grey yellow) R8 - 180 K ohm resistor (brown grey yellow) P4 - 50 K ohm, .12W potentiometer (503) (top adjust, next to Q1) (ok to solder on top of board) Q2 - MPSA44 NPN transistor R10 - 10 K ohm resistor (brown black orange) R9 - 10 K ohm resistor (brown black orange) Q3 - MPSA44 NPN transistor P5 - 50 K ohm, .12W potentiometer (top adjust) (ok to solder on top of board) Q4 - MPSA44 NPN transistor R13 - 10 K ohm resistor (brown black orange) R31 - 10 K ohm resistor (brown black orange) R34 - 10 K ohm resistor (brown black orange) R5 - 4.7 K ohm resistor (yellow purple red) R11 - 4.7 K ohm resistor (yellow purple red) R7 - 4.7 K ohm resistor (yellow purple red) R12 - 4.7 K ohm resistor (yellow purple red) C11 - .1 u F (104) capacitor C222 - (the one next to U4) .1 u F (104) capacitor C33 - .1 u F (104) capacitor C44 - .1 u F (104) capacitor C55 - .1 u F (104) capacitor (if installing battery backup, use the 1,000uF, 6.3 Volt cap instead) U5 - 8 pin IC socket NOTE ORIENTATION R25 - 47K ohm resistor R22- 47K ohm resistor U4 - 8 pin IC socket NOTE ORIENTATION R24 - 47K ohm resistor R23 - 47K ohm resistor U6 - 8 pin IC socket NOTE ORIENTATION U3 - 20 pin IC socket NOTE ORIENTATION D77 - 1N4001 diode U1 - 28 pin IC socket R20 - 2.2 K ohm resistor ( red red red ) R21 - 2.2 K ohm resistor ( red red red ) R18 - 2.2 K ohm resistor ( red red red ) S1 - tactile pushbutton switch ( fast set ) S2 - tactile pushbutton switch ( slow set ) PART 4, wires from the board to the crt socket : Use 20 gauge wire , 8 “ lengths , (or longer depending on where you want to mount crt , it will work ok with lengths of 12”) Solder a wire to K (next to Q10) for the CRT cathode Wire to F (wiper of P1) for the CRT focus Wire to A (wiper of P2) for the CRT anode Wire to G (next to Neon bulb) for CRT control grid Wire to X1 for CRT X1 plate Wire to X2 for CRT X2 plate Wire to Y1 for CRT Y1 plate Wire to Y2 for CRT Y2 plate Wire to f (near to R1) for CRT filament Wire to f for other CRT filament For a DG7/32 crt: DG7-32 pin board 1 f 2 G 3 K 4 F 5 nc 6 Y2 7 Y1 8 A 9 X2 10 X1 11 nc 12 f pin 1 & 12 - filament voltage across these should be 4-6VAC Read all other pins referenced to ground (0VDC): PIN VOLTAGE 2 ~ -300VDC 3 ~ -295VDC 4 ~-150VDC 6,7,8,9,10 ~150-250VDC For the DG7-32, R99 & R4 = 330K, R6 & R8 = 220K 6Lo1i pinout: Pin board 1 f (filament/heater) 2 K (cathode) 3 G (grid) 4 F (focus) 5 NC (no connection) 6 NC 7 X2 8 X1 9 A (anode) 10 Y1 11 Y2 12 NC 13 NC 14 f Voltage measurements, using ground (0 volts) as reference (tab of 7805 regulator is good point for ground contact) From ground to pin should be: 2 (K) = -295VDC 3 (G) = -300VDC 4 (F) = -150VDC 7 - 11 (X1, X2, A, Y1, Y2) = 150VDC to 250VDC voltage measured across f - f should be about 4 - 6VAC These measurements are approximate, but should be close. For the 6Lo1i, R99 & R4 = 220K, R6 & R8 = 180K Part 6 - bringing the crt to life PLEASE NOTE that it's important to complete these steps before adding the gps or wifi module (if adding this option) Ok now you should be ready to fire up that crt , set P1 - P5 in the middle position of their adjustment . Now set P7 (side adjust) all the way to the left (counter clockwise), set P6 (side adjust) all the way right (clockwise). Use a short piece of hookup wire that will fit snugly in the IC socket 's pin sockets , and connect pin # 28 on U1 to pin # 20 on U1. Use another jumper wire to connect pin #8 and #26 on U1. Plug in the AC power cord and in a few minutes, hopefully you will begin to see a blob or dot in about the middle of the screen. Adjust P1 until the spot is as round as it can get. Adjust P2 until it is as sharp as it can get . P3 (brightness) may also need to be adjusted to get the optimal focus. Readjust P1 Unplug the cord . Now plug in the two IC’s marked “4132“ into the sockets U5 & U4, being careful to NOTE the orientation (the notch should be "up", or towards the middle of the board) Plug the AC power cord back in. Adjust P6 & P7 (side adjust) to their middle positions . You should see the spot again , center it & readjust P1 & P2 for the best focus / roundest spot Now unplug the power cord , and insert the IC marked 12f629 into socket U6. Plug power cord back in, and when the spot reappears, watch for it to move a slight bit left / right up / down. This means the shifter is working. Unplug the power again , and insert the chip marked "7528" ( 20 pin ) into U3, noting the proper orientation, and the biggest chip marked 18f26K20 into U1. Power up again, & this time push S2 once, now you should see the clock face. Adjust P4 & P5 to the desired size, then readjust P1 & P2 to the best possible focus. The Wifi module assembly: R1 - 1K resistor R2 & R3 are 10K resistors R4 - 2.2K ohm resistor C1 - 10uF, 6.3 - 50V electrolytic capacitor Q1 - 2N3904 NPN transistor U1 - 1700 3.3VDC regulator LED C2 - 104 (.1uF) capacitor S1 - tactile pushbutton (normally open) switch 8 - pin socket for module 5 pin header to plug into 5 pin socket on main baord Insert Wifi module aligned with outline on board. Please follow the directions in "WifiModuleConnect" to connect to your network.