This is only a preview of the April 1993 issue of Silicon Chip. You can view 48 of the 96 pages in the full issue, including the advertisments. For full access, purchase the issue for $10.00 or subscribe for access to the latest issues. Articles in this series:
Items relevant to "Build An Audio Power Meter":
Items relevant to "Three-Function Home Weather Station":
Articles in this series:
Items relevant to "12VDC To 70VDC Step-Up Voltage Converter":
Articles in this series:
Items relevant to "A Digital Clock With Battery Back-Up":
|
Digital clock with
battery back-up
Ever fancied building a clock? Well, here's
your chance to get stuck into some basic
digital electronics & build yourself a useful
timepiece. It has battery back-up, automatic
display dimming at night, AM/PM indication
& a 4-digit LED display.
By DARREN YATES
Digital electroni.cs is a large and
diverse field. Apart from the computer industry, it's now used in everything from telephones to washing
machines to the humble digital alarm
clock next to your bed.
However, if you look inside your
clock, you won't recognise much in
the way of electronic circuitry. What
you will find is a PC board on the
back of a LED display, with a black
"blob" in the centre. Embedded inside this blob is a single large scale
80
SILICON CHIP
integration (LSI) chip which contains
virtually the entire clock circuit.
Of course, conventional LSI clock
chips are still made but, with the advent of cheap digital clocks, they are
now difficult for the do-it-yourself
enthusiast to obtain. These LSI chips
also teach you nothing about digital
electronics.
This design changes that situation
by not using a dedicated LSI chip.
Instead, it uses nine readily available
CMOS ICs, some of which you may
already have sitting in your junkbox.
The main features of our clock are
listed in the specifications panel.
Block diagram
The main sections of the clock are
shown in the block diagram of Fig.1.
It uses an accurate frequency reference which is divided down and used
to clock a number of BCD counters
and a latch. There are three BCD
counters in all - two to count the
minutes and one to count the hours
from 0-9. All three counters directly
drive 7-segment LED displays.
The latch provides the 10-hour
count and drives two segments of a
fourth LED display.
Let's go through the block diagram
step-by-step and explain how it all
works.
Basically, you can think of a clock
as a specialised counter that increments once every minute. Unlike a
conventional counter, it is presettable
and has a somewhat unusual count
sequence; eg, it counts from 59 to 00
and from 12 to 1.
Let's begin with the section that
generates the pulses. These have to be
accurate and that means that we can't
use a simple RC-type oscillator to do
the job. This type of oscillator drifts
with temperature and any frequency
variations can translate into quite large
errors.
What's needed then is a very accurate frequency reference and this has
been obtained by using a digital watch
crystal. This type of crystal oscillates
at 32. 768kHz and this is divided by
16,384 to obtain an accurate 2Hz
square-wave signal.
To obtain one pulse every minute,
we need a frequency of 0.0166Hz and
so our 2Hz signal must be further
di'rided by 120. This is achieved by
first passing it through a divide-by-2
stage and then through a divide-by-60
stage.
The resulting 0.0166Hz signal is
fed into counter 1, which is the 0-9
minutes counter. Its carry out (CO)
output goes high on the 10th count
and clocks counter 2 which counts
the tens of minutes.
Because the maximum count that
the minutes counter can display is 59,
we have to detect the 60th count and
this is done by checking counter 2's
display driver outputs. When the 60th
count is reached, the first two counters
are reset and counter 3 is incremented
by one.
Finally, the CO output from counter 3 clocks a latch when a count of 10
hours is reached. This latch not only
drives the two segments of the fourth
LED display but also drives a display
latch to give AM/PM indication. It
also provides a reset clock pulse to
counter 3 for the transition from "12"
to "1" (more on this later).
Time setting is achieved by feeding
the 2Hz clock signal directly into
counters 1 and 3 so that the minutes
and hours can be incremented separately. This makes time -setting a
breeze.
Circuit diagram
Fig.2 shows the full circuit details
of the Digital Clock. Note that all the
IC numbers on the block diagram can
be related directly to the circuit diagram. IC5 is the 0-9 minutes counter,
IC6 the minutes tens counter, IC7 the
0-9 hours counter, and IC8a & IC9a
the 10-hour count and latch circuit.
I
CRYST AL
OSCILLATOR
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TIME SET
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Fig.1: block diagram of the digital clock. It uses a crystal controlled oscillator
(ICl) to generate an accurate reference frequency & this frequency is then
divided down & used to clock three BCD counters (IC5-IC7) & a latching circuit
(IC8a & IC9a). The counters & the latching circuit in turn drive four 7-segment
LED displays, while another latch (IC8b) drives the AM/PM indicator.
In greater detail, IC1 is a CMOS
4060 14-bit counter and oscillator
which has its frequency set by a
32. 768kHz watch crystal. A 33pF trimmer capacitor provides the correct
loading for the crystal to ensure that
it starts reliably, while VCl allows
Specifications
• 4-digit LED readout.
• 12-hour operation.
• separate hours & minutes time
setting.
• automatic display dimming at
night.
• AM/PM indication.
• crystal-controlled timing.
• 12VDC plugpack power
supply with back-up battery.
the crystal frequency to be trimmed
slightly so that the clock keeps accurate time.
The output at pin 3 of IC1 is the
required 2Hz square-wave signal (ie,
the crystal frequency is divided by
214 ). This signal is divided by flipflop
IC2a to produce a 1Hz signal on pin 1
which, among other things , is used to
flash the two centre decimal points
on the display to separate the hours
and minutes digits.
The 1Hz signal from IC2a is also fed
to a divide-by-60 cjrcuit based on IC3 ,
a 4518 dual BCD counter. Both
counters inside this IC are connected
in cascade, with AND gate IC4a used
to detect a '6' output from the second
counter.
Pin 4 of IC4a drives an RC network consisting of a lkQ resistor and
a .001µF capacitor. Each time IC3
APRIL
1993
81
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The switch board carries the three timesetting switches & the light dependent
resistor (LOR). It is mounted on 9mm spacers on the lid of the case & is
connected to the timekeeping PC board via flying leads.
reaches a count of 60, pin 4 goes high,
the capacitor charges and pin 15 of
IC3 is pulled high. Thus, IC3 is reset
to 00 a short time after the count of 60
is reached.
As a result, each time IC3 counts to
60, pin 4 ofIC4a briefly switches high.
IC4a thus delivers a 0.016Hz pulse
train (ie, one pulse per minute) and
this signal clocks BCD counter IC5 via
Dl.
IC5's CO output in turn clocks IC6
(the minutes tens counter) at every
lath count, as described previously.
It's here that we strike the first wrinkle. When IC6 reaches a count of six,
two things must happen: (1) IC5 & IC6
must both be reset to zero; and (2) a
clock signal must be applied to hours
counter IC7.
As it turns out, we can easily detect
the 6th count by monitoring the "b"
and "e" outputs from IC6. When a '6'
is to be displayed, the "b" output segment is low and the "e" segment out-
◄ Fig.2 (left): all the IC numbers on the
block diagram can be related directly
to the circuit diagram. IC5 is the 0-9
minutes counter, IC6 the minutes tens
counter, IC7 the 0-9 hours counter,
and IC8a & IC9a the 10-hour count
and latch circuit. The timing circuit is
based on a 14-bit counter/oscillator
(ICl) & a 32.768kHz watch crystal.
put is high. These two conditions only
occur together at the 6th count.
Thus, on the 6th count, transistor
Ql will be off and pin 8 of IC4b will
be high. Pin 9 of IC4b also goes high
on the 6th count and thus pin 10
switches high and clocks hour counter IC7 via DZ. IC4b then resets IC6 a
short time later via the RC delay circuit connected to its output.
Because the time constant of this
RC circuit is very small, the observer
doesn't see the '6' appear. The output
pulse from IC4b is still long enough to
clock hours unit counter IC7, however.
Hours counter
This is where things start to get a
little tricky. That's because IC7 must
cycle from 1 to 9 to O (as in 1am-10am
or 1pm-10pm), then from 1 to 2 (as in
11am-12pmor 11pm-12am), then from
1-0 again and so on.
This sequence is impossible for a
4026 UP counter to do on its own but
it can be done by adding a small
amount 0f extra circuitry based mainly
on IC9a. We'll look at this in some
detail shortly.
IC8 is a 4013 dual D-type flipflop,
with IC8a connected as a latch to drive
the leading display. Because this display either shows a '1' or is off, segments "e" and "f" are tied together via
1.8kQ resistors and driven by the Qbar output of IC8a via transistor QZ.
When Q-bar is low, Q2 turns on and
the two segments light to show a "1".
Conversely, when Q-bar is high, QZ
and the segments are off.
IC8a is clocked by the CO output of
IC7. When IC7 reaches a count of 10,
its CO output goes high and Q-bar of
IC8a goes low, thus turning on Q2 and
the "e" and "f" segments of the leading hours digit.
Now let's see how IC7 cycles
through its count sequence. As already discussed, clock pulses are applied to IC7 at regular 1-hour intervals via diode DZ. Assume for the
moment that the time is currently 1:59;
ie, IC7 is at a count of "1". When the
next clock pulse arrives , IC7 goes to a
count of 2 (ie, we have 2:00 on the
displays) and this causes the "2OUT"
pin (pin 14) to go low.
This low transition is ignored by
the clock input of IC9a, since this
flipflop can only change state when
its clock input goes from low to high
(provided its Reset input is low). When
the next clock pulse occurs, IC7 goes
to a count of "3" and pin 14 of IC7
goes high again
This high is applied to the clock
input of IC9a but IC9a ignores the
clock pulse on this occasion. That's
because its reset input (pin 4) is held
high by the Q-bar output from IC8a.
However, when the count in IC8a and
IC7 reaches 13, Q-bar of IC8a is low.
IC9a thus switches its Q output (pin
1) high on receipt of the clock pulse
and this resets both IC7 and IC8a.
Q-bar of IC8a now goes high again
and turns off transistor Q2 and the
leading digit (ie, the leading digit is
blanked). At the same time, IC7 is
reset to "0".
But we don't want the hours units
display to show "0"; we want it to
show a "1 " instead. That's achieved
by using the Q-bar output of IC8a to
clock IC9b when it switches high to
turn off the leading hours digit. When
that happens , IC9b 's Q output
switches high and feeds a clock pulse
to IC7 via D3 to that IC7 immediately
advances to a count of 1.
IC9b then resets itself almost immediately via the RC time constant on
its pin 13 output.
In summary then, the hours
counters (IC7 & IC8a) count to 12 and
are reset to O on the 13th count. IC7 is
then immediately clocked to produce
a "1" on the display. This all happens
very quickly so that, as far as the
APRIL
1993
83
-
signal derived from pin 4 ofICl. If the
ambient light level is high, the resistance of the LDR is low and the output
from IC4d is also low. Conversely, if
the light level is low, the LDR's resistance is high and IC4d gates through
the 512Hz square-wave signal from
IC1.
IC4d drives PNP transistor Q4 via a
47kQ base current-limiting resistor.
When IC4d's output remains low (ie,
the light level is high), Q4 turns on
and thus Q5 also turns on and the
displays are driven at a 100% duty
cycle to provide maximum brightness.
Conversely, when the light level is
low, IC4d switches Q4 and thus Q5 on
and off at a frequency of 512Hz. Q5 in
turn switches the displays on and off
at this frequency to reduce the display brightness .
~
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Fig.3: install the parts on the main PC board & the display PC board as shown
here. Take care with the orientation of polarised parts & note particularly that
DISP2 & DISP4 must be installed upside down on the display board (ie, with
their decimal points at top left).
observer is concerned, the display goes
straight from "12:59" to "1:00".
Q3, IC4c and ICBb are used to drive
the AM/PM indicator. Q3 inverts the
2OUT output from IC7 and drives one
input of AND gate IC4c, while the Q
output of IC8a drives the other input
(pin 12) of the AND gate. Pin 11 of
IC4c thus clocks IC8b every 12 hours
to toggle the AM/PM indicator.
The AM/PM indicator itself is actually the decimal point on the leading
digit. A very simple trick is used so
that it appears in the top lefthand
corner of the display - the display is
LOR
$2
~
Display dimming
0
Fig.4: the switch board carries just four
components: the three timesetting
switches (S1-S3) & the LDR. Make sure
that the flat side of each switch is
oriented as shown.
84
SILICON CHIP
installed on the PC board upside
down!
Pushbutton switches S1, S2 and S3
perform the time setting function. To
set the time, S1 (TIME SET) must be
held down and then either S2 pressed
to set the hours or S3 pressed to set
the minutes.
The circuit work like this: when S1
is pressed, 2Hz clock pulses from IC1
are coupled through to S2 and S3. If
S2 is now pressed, these 2Hz pulses
are differentiated by a .0015µF capacitor and fed to ·pin 1 of IC7 to increment the hours display. Similarly, if
S3 is pressed, the minutes 0-9
counter is clocked.
IC4d, Q4, Q5 and an ORP12
light dependent resistor (LDR)
provide the automatic dimming
function for the LED displays.
The LDR and its series 3.3kQ resistor form a variable voltage
divider, the output of which depends on the ambient light level.
This output is fed to one input of
AND gate IC4d.
The other input of IC4d is
driven by a 512Hz square-wave
Power for the circuit is derived from
a 12V DC plugpack supply. As shown
on Fig.2, the incoming DC is fed via
reverse polarity protection diode D4
to a 3-terminal 12V regulator. Two
separate supply rails are then derived
from the output of the regulator via
isolating diodes D5 and D7. The +Vl
rail powers all the timekeeping circuitry, while the +VZ rails powers the
LED displays via the dimming circuit
(Q4 & Q5).
A 6V backup battery is used to supply the timekeeping circuitry if the
mains fails. This battery is isolated
from the +Vl rail via D6 which is
normally reverse biased. When the
mains fails however, D6 becomes forward biased and the battery takes over
and supplies power to the +Vl rail.
During this time, D5 is reverse biased and so the LED displays are
blanked. This was done to conserve
the batteries in the event of a long
blackout. The LED displays come back
on again to show the correct time as
soon as the mains power is restored.
Construction
All the components for the digital
clock ·(except for the 3.5mm power
socket) fit on three PC boards: a main
board (code 04101931) which accommodates all the timekeeping circuitry;
a display board (code 04101932)
which holds the four LED displays;
and a switch board (code 04101933)
which holds the timesetting switches
and the LDR.
Before installing any of the parts,
The display board is soldered at right angles to the main board via matching
edge-connector pads & must be adjusted so that the LED displays line up with
the perspex viewing window (see text). Wrap the battery in foam insulation to
prevent it from shorting other components when the lid is attached.
check all three boards for etching defects by comparing them with the published artworks. When you're satisfied that everything is correct, the parts
can be installed on the main PC board.
Fig.3 shows the parts placement
details. Begin by installing PC stakes
at all external wiring points, then install the wire links, resistors and capacitors. Make sure that the wire links
are straight so that they don't short
against other parts.
You can straighten the link wire if
necessary by clamping one end in a
vice and then stretching the wire
slightly by pulling on the other end
with a pair of pliers.
The semiconductors can now be
installed on the PC board, followed
by trimmer capacitor VC1 and the
32.768kHz watch crystal. Be sure to
use the correct part at each location
and check that all parts are correctly
oriented.
In particular, check the transistor
type numbers carefully and note that
all the ICs face in the same direction.
The 3-terminal regulator is installed
with its metal tab towards the adjacent power diodes (see Fig.2 for the
pin connection details).
Display board
This board will only take a few
minutes to assemble since it only carries the four LED displays plus two
wire links. There is a catch though:
displays 2 and 4 must be installed on
the board upside down (ie, their decimal points must be at top left). These
two displays are marked with an asterisk on the parts layout diagram
(Fig.3).
The other two LED displays (1 & 3)
are installed in the usual manner (ie,
decimal points at bottom right). Push
all the displays down onto the board
as far as they will go before soldering
their pins.
Once the display board has been
completed, it can be attached at rightangles to the main board by lightly
solder tacking two pairs of edge connectors together. Adjust the display
board so that its bottom edge sits about
RESISTOR COLOUR CODES
a
a
a
a
No.
1
4
7
a
a
a
a
a
1
26
3
Value
4-Band Code (1%)
5-Band Code (1%)
4.?MQ
100kQ
47kQ
22kQ
4.7kQ
3.3kQ
1.8kQ
1kQ
yellow violet green brown
brown black yellow brown
yellow violet orange brown
red red orange brown
yellow violet red brown
orange orange red brown
brown grey red brown
brown black red brown
yellow violet black yellow brown
brown black black orange brown
yellow violet black red brown
red red black red brown
yellow violet black brown brown
orange orange black brown brown
brown grey black brown brown
brown black black brown brown
APRIL
1993
85
PARTS LIST
1 PC board, code SC04101931,
154 x 88mm
1 PC board, code SC04101932,
102 x 37mm
1 PC board, code SC04101933,
82 x 51mm
1 front panel label
1 switch label
1 2.5mm DC socket
1 battery snap connector
1 ORP12 light dependant resistor
3 pushbutton !'170mentary
switches (S1 ,S2,S3)
1 plastic case, 186 x 125 x 50mm
(Rod Irving Cat. H-10116)
8 9mm x 3mm tapped spacers
8 25mm x 3mm machine screws
1 32.768kHz watch crystal (Rod
Irving Cat.Y-11125)
1 4 x AA square battery holder
4 1.5V AA batteries
Semiconductors
1 4060 oscillator/14-bit counter
(IC1)
3 4013 dual D flipflops (IC2,
IC8,IC9)
1 4518 dual 4-bit BCD counter
(IC3)
1 4081 quad 2-input AND gate
(IC4)
3 4026 decade counter/display
drivers (IC5-IC7)
2 BC548 NPN transistors
(01 ,03)
3 BC558 PNP transistors
(02,04,06)
1 BC337 NPN transistor (05)
1 7812 3-terminal regulator
4 HDSP-5303 common-cathode
?-segment LED displays
3 1N914 signal diodes (D1 -03)
4 1N4004 silicon diodes (D4-D7)
Capacitors
1 100µF 25VW electrolytic
1 100µF 16VW electrolytic
6 .001 µF 63VW MKT polyester
2 100pF ceramic
1 33pF ceramic
1 5-30pF trimmer capacitor (VC1)
Resistors (0.25W, 1%)
1 4.7MQ
4 100kQ
7 47kQ
1 22kQ
1 4.7kQ
1 3.3kQ
26 1.8kQ
3 1kQ
Miscellaneous
•
Tinned copper wire, hook-up
wire, screws, nuts, washers.
86
SILICON CHTP
Fig.5: this fullsize artwork can
be used as a
drilling template
for the switches
& the LOR.
LDR
+
Time Set
Hours
Minutes
+
+
+
5mm below the copper side of the
main board before making these two
connections and leave the remaining
connections until later in case some
adjustment is required.
Switch board
Fig.4 shows the wiring details for
the switch board. Note that the three
pushbutton switches must be correctly
oriented, otherwise they will be behave as though they are permanently
closed. In each case, the flat side of
the switch body must face towards
the top of the board.
The only other part on the switch
board is the LDR. It can be installed
etther way around and should be
pushed down so that its top surface is
no more than 9mm above the PC board.
Final assembly
The prototype was built into a black
ABS plastic case measuring 186 x 125
x 50mm (see parts list). This case
comes with a integral screw supports
on both the base and lid and these
will have to be removed using an oversize drill bit. The front panel label is
then attached to its panel and the
cutout made for the LED displays.
This cutout is best made by drilling
a seri.es of small holes around the
inside perimeter of the marked area,
then knocking out the centre piece
and filing the job to a smooth finish.
This done, glue a piece ofred Perspex
to the back of the panel to provide the
viewing window.
The front panel can now be slid
into the base and the main board assembly .introduced so that the displays sit directly behind the cutout.
Position the board so that the displays are almost touching the Perspex,
then mark;out and dr-ill the fpur cor-
ner mounting holes in the base.
The main board assembly is mounted in the case on 5mm spacers. Secure the board at two diagonally opposite mounting points to begin with,
then check that the displays line up
correctly with the viewing window. If
they don't, adjust the display board as
necessary, then solder the remaining
edge connector pads.
Finally, the switch board can be
mounted on the lid of the case, the
3.5mm power socket installed on the
rear panel and the wiring completed.
The exact location of the switch board
is not critical but make sure that it's
far enough back to clear the display
board.
When you have decided on the exact location, attach the label and use
it as a template for drilling the holes.
A small pilot drill should be used
initially for drilling the switch and
LDR holes and the holes then enlarged
to size using a tapered reamer.
This done, conneot eight 150mmlong flying leads to the switch board,
then mount the board on the lid using
9mm spacers, machine screws and
nuts. The wiring between the two PC
boards and to the DC power socket
can now be completed and the battery
snap connector fitted.
Testing
Now for the smoke test. Connect
the DC plugpack supply and switch
on - you should immediately get a
readout on the displays, although it
might not make much sense at this
stage. That's because the 4026 counters
can switch on in a random mode and
produce incorrect symbols.
To correct the displays, all you have
to do is press the time setting buttons
(ie, Time Set + Hours and Time Set +
0
0
0
If all is well so far, connect the 6V
b!lck-up battery (a 9V battery will also
do the job), set the time and switch off
the mains power. The display should
now go out but the clock should continue to function. Leave the mains
power off for a few minutes, then
switch it back on again. The display
should now come back on and show
the correct time. Check that diodes
D5 and D6 are correctly oriented if
you strike problems here.
Finally, check that the display dim-
~
flllll!J-
u
00
00
~
:
0
Fig.6: check the PC boards for etching defects against these full-size
patterns before installing any of the parts.
Minutes) until the counters are clocked and revert to a valid condition.
If the clock doesn't work, switch off
and check for wiring errors. In particular, check for incorrect parts placement on the PC boards and for shorts
between soldered joints on the back
of the boards. If the displays don't
make much sense, check for shorts
between the display segments and that
the displays have been correctly oriented (displays 2 & 4 must be installed upside down).
0
04101933
ao-------o~o
o0i----a00
0
0
ming feature works by covering the
viewing hole for the LDR. The display
should dim immediately when the
hole is covered.
SC
I. _____. .I
Classic Clock
Fig. 7: the front panel cutout is made by drilling a series of small holes & then knocking out the centre piece.
APRIL
1993
87
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