Gated Clock

Hi! Looks like you stumbled upon this project before it's completely finished. Maybe one of JLCPCB's engineers decided to scan the QR code? :D

Anyway, the point of this project is to:

• build a functional digital clock out of only discrete logic gates (74LVC1G10 3-input NANDs to be specific) and passives;
• make sure the entire circuit for as far as this is needed to make it work is visible on the front, with LEDs for (almost) all digital signals;
• actually make it look pretty; and
• actually make it useful.

Note that none of the above include anything about BOM cost. See the section on cost below.

License

Let's get the fine print out of the way first. The license for this stuff is Creative Commons BY-NC-SA 4.0. See also the LICENSE file for the full plaintext.

The only exceptions to the license are the 3D models of the electrical parts I used for the renders (basically, any of the .blend files in the models directory); some of these are converted directly from the STEP files provided by the part manufacturers and are thus licensed under different terms. I'm honestly not too sure what these terms are, since most of the legalese they try to make you read is about limitation of warranty with regards to model accuracy.

How does it work

The short version is as follows.

• The electricity grid oscillates at 50Hz or 60Hz depending on where you live, with stipulations about long-term accuracy by law in most places. So, while synchronizing clocks to the grid frequency is old-fashioned, it's actually a supported use case.

• A circuit based on a capacitive dropper, an optocoupler, and some active filtering translates the high-voltage AC signal to a logic-level clock source.

• A bunch of NAND-gate-based D-flipflops divide this frequency down to increasingly lower frequencies. Divider circuits exist for a factor 2, factor 3, and factor 5. The chain used is as follows:

  • divide by 5 to get 10Hz or 12.5Hz;
  • divide by 5 or 2x3 (jumper-configurable) to get to 2Hz;
  • divide by 2 to get to 1Hz;
  • divide by 2 to get to 1/2Hz (= 2 seconds);
  • divide by 5 to get to 1/10Hz (= 10 seconds);
  • divide by 2 to get to 1/20Hz (= 20 seconds);
  • divide by 3 to get to 1/60Hz (= 1 minute);
  • divide by 2 to get to 1/120Hz (= 2 minutes);
  • divide by 5 to get to 1/600Hz (= 10 minutes);
  • divide by 2 to get to 1/1200Hz (= 20 minutes);
  • divide by 3 to get to 1/3600Hz (= 1 hour);
  • divide by 2 to get to 1/7200Hz (= 2 hours);
  • divide by 5 or 2 based on the last divider to get to an average of 1/28800Hz (= 8 hours);
  • divide by 3 to get to 1/86400Hz (= 1 day).

  Note that the division works very different than how you would do it in an FPGA. In an FPGA you'd probably have binary counters with a clock-enable signal on the registers and call it a day. But that requires considerably more logic to do. The dividers here are all clocked based on the previous output, which omits the clock enable requirement, and they are based on shift registers rather than regular binary counters. Note also that the dividers are chosen such that each decimal digit of the time it represents has its own set of counters, with states independent from the counters for the other digits.

• A bunch more NAND gates in an and-or-invert configuration take the state signals and convert them to (active-low) 7-segment display signals for the clock readout. These drive the LEDs more-or-less directly.

• A clock needs to be configurable, of course. It'd be a bit inconvenient if you'd have to turn it on at midnight exactly. Therefore, the clock signal for the minutes and for the hours passes through a configuration circuit with a three-way switch that allows you to override it: the circuit either forwards the clock signal in one extreme position of the switch, overrides it high in the middle position, and overrides it low in the non-latching, opposite position. The subsequent dividers increment on the rising edge of the clock signal, so releasing the switch from its non-latching position always increments the time, and going from the passthrough position to the middle position may increment the time (this is an unwanted side effect that would require an XOR to avoid, which would take more gates than I had room for).

• Flipflops require a reset signal to be put in a well-defined state. A power-on reset circuit asserts this global reset line to do this at powerup, and a button allows you to override. This button could also be used to synchronize the seconds counter, as the clock starts at 00:00.

• Because I don't like manually configuring clocks, and especially setting the time with the above interface would be annoying, there's also a microcontroller in here somewhere. This microcontroller can also override the minutes and hours clock signals, so it can also set the time. It can also read and override the non-latching position of the manual configuration switch, allowing it to convert its function to increment the time when you're pushing it outward rather than when you release it, and to auto-increment it when you hold it in the extreme position. Different-color LEDs are used to indicate the state of these override signals, so it's clear when the microcontroller is doing something. The microcontroller can synchronize itself using a GPS module (GPS is about the most accurate time reference you can get in your home that isn't a literal atomic clock!).

• Because I had some room left on the board visually, I added a sort of synchroscope to it for showing the speed difference between the GPS-referenced and grid-referenced time signals. This is completely unnecessary for the operation of the clock, but I'm generally also interested in seeing the grid frequency fluctuations, so it's kind of a two-projects-in-one thing for me.

• The microcontroller can also override the reset signal, read and override the grid frequency clock signal, and read and override the state of the 7-segment display. This allows it to do fancy stuff like a self-test of the circuit (so you don't have to wait a day for it to pass through all states), and to override the display with a menu structure in conjunction with three soft buttons.

• Finally, the microcontroller controls LED brightness and (in case of the 7-segment display) color using not only PWM but also analog dimming. Basically, I hate flickering LEDs and LEDs that are way too bright, and couldn't make up my mind about the display color so I rammed some RGB LEDs in there.

For more details, check out the primitives and subcircuits directories. Most of the circuitry is ASCII-art'ed in there, with more elaborate descriptions.

How did you design it

Yeah, about that. I'm used to working in Altium, but didn't want to use it for this because:

• arcs, arcs everywhere;
• it's ridiculously slow nowadays;
• I only have access to a sponsored license through a student association which has nothing to do with this project, and their licenses are unaffordable when you're not designing PCBs for profit full-time.

I heard KiCad is good and tried it, but started hating my life within a few hours. Altium has spoiled me.

So, I did what any reasonable person would do and abandoned the project built my own PCB design flow from scratch using Blender and Python. More details on this are in the README file of the primitives directory.

The practical upshot of doing everything from scratch however is that I could hook into it wherever I wanted. For example, the Python scripts also generate VHDL to test the actual circuit logically, with some best-effort timing estimates even. After generating everything, you can just run vhdeps ghdl or vhdeps vsim (see the vhdeps for more info) and it will check everything (GHDL is super slow for the main test case however). It also allowed me to make proper no-compromises 3D models of the PCBs, something that I always wished Altium would let me do. I don't just want the holes and outline, damnit, I want the copper traces and silkscreen and soldermask and whatever as well! Seeing as part of the goals is for it to be pretty, being able to make proper renders in advance was pretty important for me.

How do I get one

tl;dr: I do not sell these, nor do I plan to do so personally. You're free to build one yourself though (and I'd love to hear about it if you do!), and I'm open for discussion on commercializing it if that's your cup of tea.

BOM cost

I personally didn't care too much about this. I mentally give myself an approximate monthly allowance for hobby stuff, and because this project has taken so long already, I'm actually way under budget. That means I did basically no cost-optimization.

I can't put an accurate price tag on the thing because I split everything over multiple orders while prototyping, but I would expect the whole thing to set you back somewhere around €500-€800, assuming you already have the necessary equipment for SMD soldering and a 3D printer with sufficient build area.

A lot of that is startup cost though. For example, the main PCB is ~€200 for the minimum quantity of five even at insanely cheap places like JLCPCB. One does not simply a 40x40cm four-layer PCB with white soldermask, I guess. The acrylic lasercutting also has a significant startup cost, and of course part cost at Mouser or whatever distributor you prefer will go down for higher volumes as well. The price per clock probably drops off to around €300 or so per clock for five of them.

But if it's so much cheaper at scale, why not build a bunch of them and sell them?

I can't believe I'm writing this; it feels so "full-of-myself". The only reason I'm putting this here is because multiple people have asked me to make one for them.

No, I won't personally be commercializing these. I honestly can't be bothered dealing with things like shipping, managing payments, taxes, supply chain, redesigning the whole thing for pick & placing rather than manual soldering, and so on. I'm the kind of person to hand perfectly resellable stuff over to a local goodwill or whatever for free because trying to do anything more stresses me out so much that it's just not even close to worth it.

However.

I love the idea of this thing hanging on someone else's wall as well. Therefore, I made sure not to use any software or whatever that does not allow commercial usage, and I did make sure that the thing should work worldwide (50/60Hz selection, 100-250VAC input voltage, and using GPS instead of DCF77 for time sync). So, in case someone with a more entrepreneurial spirit than I have wants to pick things up from where I left off to sell these for a profit, it should be no problem aside from the things I mentioned above. I would expect some compensation (hence why I've slapped a noncommercial license on this thing for now), but ultimately this is just a hobby project for me. Mostly I just want to know about it if someone does this. You can contact me at .

Above does not apply if you just want to build one yourself and sell the other four to friends to recoup some of the one-off costs, like I might do. If that's all you want to do, go for it; I'd still like to know out of curiosity, but I don't expect anything in return. The limit for me would be when you start making profit.

Okay, then how do I build one

You're going to need the following things.

• A Linux computer or VM, probably. Some or all of it may work on Windows/Mac too, but your mileage may vary. The following software is needed:

  • Blender. I'm using version 2.91. Blender is good with compatibility, but with all the scripting going on, you might want to get that exact version. The makefiles look for blender-2.91 in your PATH first if it exists, before defaulting to just blender.
  • Python 3.x. I'm using 3.6 because I'm too lazy to upgrade my OpenSUSE install. But it probably doesn't matter too much if it's newer than that.
  • Gerbertools. Depending on how lazy I am you might have to build it yourself, but that should be pretty easy.
  • The following regular Python modules: matplotlib (I'm using 3.1.0, but it's only used to render text, so probably doesn't matter) and qrcode (6.1, may or may not matter).
  • ImageMagick for the convert command.
  • Inkscape for making PDFs out of SVGs (part of the acrylic plate pipeline, you'll probably have to customize/redo this though).
  • git, as in the commandline version, should exist. It's used by the generator to tag the generated boards with the current revision.
  • make is abused for some things.
  • 7z (7zip) is used for packing the generated gerber files into a zip file.
  • You may also want vhdeps and a compatible simulator, if you intend to change any circuitry.

• Soldering equipment. If you've never soldered (SMD) before, this might not be the best project to start with. The LED drivers in particular are 0.5mm pitch TSSOPs with a thermal pad. The boards are designed to be hand-soldered though, so the pads are relatively long, and I took care to only connect traces to the end that you stuff the soldering iron into, so heating them up should be relatively easy. Unless you like to live dangerously, you should also have anti-ESD gear and actually use it during assembly.

• A current-limited lab power supply, multimeter, waveform generator, and oscilloscope are very much nice-to-have. I don't think it's humanly possible to solder everything correctly the first time, so you will be doing some debugging.

• A 3D-printer with at least 21x25cm build area. I'm using a Prusa MK3s with a stock 0.4mm nozzle and print in PETG. I'm not sure how much filament is used exactly. You'll want some 3D-print post-processing stuff as well, which I'm assuming you'll have if you have a printer.

• An M3 tap for inner thread.

• A source for the lasercut acrylic plates. I'm using a local Dutch shop (laserbeest.nl). Unfortunately I'm not sure if they ship internationally. Their ordering instructions are a bit "custom", so you'll probably have to change the pipeline or do some manual conversion work of the generated PDF/SVG files.

• A source for the two PCBs. I'm used to ordering from JLCPCB, but there are more of them out there.

• A source for the components. I'm using Mouser for everything now, so the generated ordering information is for them.

• A source for the Teensy LC, the GPS module, and the antenna. I got those from TinyTronics; a local shop again, but I'm pretty sure they ship internationally, or at least within Europe. Either way, the Teensy in particular shouldn't be hard to get your hands on, and you can probably jury-rig any GPS module you want in there (or leave it out entirely if you don't care enough about GPS sync). The headers you'd probably want to mount the Teensy to the support board are not included in any ordering list; you can do anything between proper male/female headers and just sticking wires through the holes and soldering them.

• Some miscellaneous parts not in any ordering list because I had them laying around:

  • 41 M3x12mm screws with a domed head of at most 6.2mm diameter and about 2mm thickness, though if you don't have a bunch of screws in stock you might want to get longer ones and cut them to size with a thread cutting tool;
  • 25 standard M3 hex nuts, 2.5mm thick;
  • a long M3 screw is nice to have to help pull the nuts into the printed parts;
  • a screwdriver for the above, obviously;
  • calipers are very useful to have lying around, if only to measure the thickness of the acrylic you got;
  • a mains power cord to mount to screw terminals on the support board (preferably with grounding lead, though this is technically not necessary due to the lack of exposed metal);
  • stuff to clean the acrylic with when you're done (I used "wasbenzine," but that stuff doesn't seem to have a proper English translation for some reason. The best translation I suppose would be pure gasoline. Contrary to what Google et al will tell you it is not white spirit, which would be "terpentine" in Dutch, and would be likely to mess up your acrylic).

• An appropriately filled wallet, because this is not a cheap project. But we went over that already.

1) File generation

If you're ordering via laserbeest and want to use the existing pipeline, you will want to set the following environment variables:

• ACRYLIC_NAME: your full name;
• ACRYLIC_EMAIL: your e-mail address; and
• ACRYLIC_PHONE: your phone number.

These are added to the SVG/PDF files that are generated for Laserbeest for their reference, as per their instructions.

You'll also want to update the header of generator/orderlist.py to select the LED color you want. Seven color schemes are predefined. At the time of writing I've only tried orange; your mileage may vary with the resistor values for other colors. LED brightness differs a lot based on color.

Once you have all that, or the computer part at least, run make in the root directory and go get coffee. It takes 20 minutes or so to generate everything on my fairly beefy computer, though most of it is single-threaded because I'm lazy, so the beefyness of your computer might not make too much of a difference.

Note that the root makefile is not at all intelligent, and may as well be a shell script. You may therefore want to comment out part of the make recipe manually while iterating to not regenerate literally everything each time. There's also generator/config.py; if you set the LAYOUT_ONLY constant, things will be way faster, but won't generate any copper, and use reduced-complexity routing for the circuit on the silkscreen.

Anyway, the pipeline generates the output directory, with about a GB's worth of files in it (hence why I don't try putting the generated files on github). The filenames should be fairly self-explanatory, at least in conjunction with the documentation scattered about this repo in the form of README files. Nevertheless, the most important ones are:

• mainboard.zip: Gerber production files for the main PCB;
• support_board.zip: Gerber production files for the support PCB;
• *.*.traces.png: circuit board assembly instructions (and copper layout);
• mainboard.laserbeest.pdf/.svg: acrylic plate production files;
• mouser.txt: Mouser ordering list; and
• tinytronics.txt: TinyTronics ordering list (the Teensy, GPS, and antenna).

2) Ordering

You should start by ordering the parts, obviously: the Mouser/TinyTronics electronics parts, the PCBs, the acrylic sheets, and the consumables if you don't have them laying around like I do.

As stated, the build process generates mouser.txt for the mouser ordering list, usable here. If things are not in stock, you'll either have to wait or look for alternatives yourself; you can specify these alternatives in generator/orderlist.py, after which you can regenerate by just running python3 generator/orderlist.py. If you (have to) go for the backorder route, I strongly recommend the "ship items as they become available" option; in my experience, Mouser doesn't reserve anything for your order, so by the time the originally problematic part is finally back in stock, something else might be out of stock again.

After you copy the part list into your basket, make sure to round up the part count, especially for uncommonly used resistor values and such: Mouser levies what I can only describe as an "asshole tax" for people who order small amounts of these, as ordering more will often cost less. I've seen an extreme case where the price break for 10+ was so much cheaper than the price break for 1+ that buying ten was cheaper than buying one! The ordering system does not notify you of this. In general, by the way, it's good practice to over-order the tiny parts a little bit, so you don't have to place a new order if you misplace or break a few of them.

As for the Tinytronics parts, the actual parts are a Teensy LC (which you can get just about anywhere), and any GPS module with a VCC|GND|TX|RX|PPS pinout using a standard 2.54mm header. You can probably source both from wherever if Tinytronics doesn't work for you. Don't forget to buy an antenna with a long lead as well; they're commonly available for use in cars. Headers to mount these are not included in the Mouser order either, so you'll need to get them yourself.

For the PCBs, everything assumes standard 1.6mm 4-layer PCBs with 1oz copper on the outer layers and something around .5oz on the inner layers. The mainboard is visible and is assumed to be built with a white soldermask and black silkscreen, but it's up to you; the support board is not visible and thus the color does not matter. Stackup was designed with 0.1mm between the outer and inner layers in mind, but I later found out that JLC only does this for green soldermask PCBs, so I ended up with 0.2mm separation. Doesn't really matter; nothing is explicitly impedance-matched. The only thing is that the trace capacitance calculations I did assume .1mm separation, but that would be the worse case anyway.

The footprints are designed for conventional soldering by hand. If you want to use solder paste with an oven or hot air, you might want to rework some footprints here and there. In particular, the support board has four components with a thermal pad (the LED drivers and the hot-swap controller), which have a large hole under the pad to provide access to a conventional soldering iron; you'll probably want to remove those holes when using solder paste.

As for the acrylic, three sheets are needed:

• Front: clear, 3mm, at least 40x40cm. Includes engraving instructions in addition to cuts.
• Highlight: opaque white, 5mm, at least 40x40cm.
• Display: opaque black, 3mm, at least 23x6cm.

The thickness tolerance of Laserbeest's acrylic source is abysmal, apparently due to how the sheets are made. So everything is designed with about +/-1mm thickness tolerance in mind. However, you may need to adjust some 3D-printed parts here and there, or you may need slightly shorter or longer M3 screws. Of particular importance is that the button and slide switch caps have the right height,

You may also need to adjust the hole sizes in the Front sheet based on laser width and how gutsy you're feeling. They need to be threaded, so the finished hole size should be 2.5mm. They are 2.35mm in the design files for Laserbeest, which worked well based on experimentation.

When you receive the acrylic, don't throw the bubble wrap it undoubtedly comes wrapped in away! It'll be useful during assembly.

3) 3D-printing

I would recommend to wait with this until you have the acrylic, because some of the parts depend on its thickness to various degrees. I was far too impatient for this, myself; just be aware that you may need to reprint parts later if you don't wait. The following parts depend on the thickness of the acrylic:

• the four quarter panels of the back shell have the clamping surface for the screw heads at just the right size for the bottom of the M3x12 screws that mate with the clear acrylic sheet to be flush with the front, so this recess depends on the thickness of the white and clear acrylic sheets;
• likewise for the "display extender" part, of which both the total height and mounting flange thickness depends on the thickness of the black and clear acrylic parts;
• the button and slide switch caps depend on the thickness of the white acrylic sheet.

The Blender sources for the parts are in the printed folder, the main one being assembly.blend. When you open it (give it time, the boolean operations and geometry involved are considerable) you will be presented with some text and a few "empties;" the axis-looking things in the middle. Their negative-Z position represents the thickness of the three acrylic sheets. You can select them by right-clicking (or left-clicking I think, if you're using the 2.8+ keybinds), and then use the transform panel on the top-right of the viewport to change the Z coordinate to negative the thickness.

Once you've done that, note the note the panel on the top-right of the screen, listing the assembly steps. You can disable visibility of all the steps except the first by clicking the eye icons, then work from there. Use numpad 7 to view the clock from the back (as you will be assembling it), or numpad 9 to view it from the front. Dragging the middle mouse button will drag the view around, holding shift as well will pan, and scrolling zooms in and out.

STL files can be generated by selecting the object you want (right/left-click as before), selecting File -> Export -> STL, ticking the "Selection Only" checkbox on the right, and picking a nice filename. You'll have to orient them onto the build plate (most parts have an obvious flat side) using the slicer for your printer.

I use PETG for everything. PLA might be fine as well, but be careful that in particular the mounting bracket is strong enough -- wouldn't want the clock to break off your wall in the middle of the night. I don't exactly consider myself to be a very experienced 3D-printer, so your mileage may vary.

Some of the parts need build plate supports, so some post-processing is involved. The slide switch caps in particular needed some TLC for me before they would slide properly, and I had to drill out the holes in the spacers for the extra-long headers. If you don't have a 1mm drill and a drill press to do this with, you can probably mess with the part and print settings until that one works straight out of the printer though, or you could probably also just eyeball the correct insertion depth for the headers when soldering.

4) Mechanical assembly (dry run)

Once you have the 3D-printed parts, acrylic, and bare PCBs, I would suggest a dry run of assembling the thing, so you know what goes where and you can be sure everything fits before all the delicate parts are populated.

• Carefully clean the clear acrylic sheet. There will be debris from the engraving; make sure it doesn't cause scratches! I personally messed up here because I assumed there would be protective foil on both sides; there was not.

• Carefully tap the holes in the clear acrylic sheet. Be patient; acrylic cracks if you're too rough. Don't use power tools!

• Place the clear acrylic sheet on bubblewrap, to avoid causing scratches and allow the button and slide switch caps to stick out slightly. The rough, engraved side should be facing up.

• Place the black acrylic sheet on top. It is not symmetrical in any direction: make sure that the colons are off-center away from the side with the synchroscope and pushbutton cutouts, and of course that the screw holes align.

• Place the printed display extender part on top of the display, again ensuring that it is oriented correctly.

• Mount the black acrylic sheet and display extender using two M3x12 screws. Be careful not to exert too much torque; threaded holes in acrylic are quite fragile!

• Place the white acrylic sheet on top. The cutout for the display should constrain it in roughly the right place aside from 180deg rotation symmetry; align based on the synchroscope engraving and/or button cutouts to avoid mounting the plate upside down.

• Place the three button caps (2x round, 1x oblong) and the two slide switch caps in the appropriate cutouts.

• Carefully place the mainboard on top. First align the slide switch caps with the slots in the PCB (and the slide switches themselves if you already soldered then), then align the pins on the bottom of the button caps with the holes in the PCB, and finally align the holes.

• If you haven't already, insert nuts in the hex recesses of the four quarter panels. There are eleven of these. Pull them in with a screw if necessary, and make sure they're all the way in (they should be flush or slightly recessed into the bosses. If your print is undersized and they fall out, you might want to glue them in.

• Slot the quarter panels together. They are all different, so there's only one way to do this. Secure them by placing screws in the four shared screw holes; the assembly shouldn't fall apart anymore after you do this, although it will still be quite floppy.

• Carefully place the panels over the rest of the assembly. The triangular screw hole pattern should be at the top of the clock, i.e. the side with the synchroscope and buttons.

• Start by tightening the four screws that hold the quarters together. Again, be careful not to exert too much force. Be especially careful if you're impatient and are doing this before you have the PCBs: you can easily break the 3D-printed parts by tightening the screws without the 1.6mm spacing provided by the PCB. Once these four screws are in, screw the remaining ten in in any order.

• Flip the clock over and make sure that the slide switches and buttons move freely. If not, disassemble in reverse order and file them down a bit. Repeat ad nauseum until they work right. Once done, place the clock down on its front again on the bubble wrap.

• Mount the wall mount bracket to the assembly with three screws. The screws mate with the triangular-pattern nuts in the top quarter panel. Be careful when tightening these the first time; the screws should be too short to reach the PCB, but if they do, you can easily damage the PCB.

• If you haven't already, insert nuts in the hex recesses of the support board interface part. There are four of these. Pull them in with a screw if necessary. If your print is undersized and they fall out, you might want to glue them in.

• Mount the panel-mount SMA antenna connector end of the SMA to uFL adapter cable that comes with the GPS antenna to the small square SMA insert part, making sure to align the flat side of the panel-mount connector with the flat side of the hole.

• Slide the above assembly into the corresponding retaining structure of the support board interface part. Note that this might require some "gentle persuasion" the first time; it should be more-or-less press-fit.

• Mount the support board interface assembly onto the main assembly with eight screws. They mate in the same way as the wall mount bracket, so be careful if the screws may be too long.

• If you haven't already, insert nuts in the hex recesses of the display light guide. There are six of these. Pull them in with a screw if necessary. If your print is undersized and they fall out, you might want to glue them in.

• Mount the display light guide to the support board using six screws. Be careful not to place it upside down; follow the silkscreen on the PCB.

• If you haven't already, insert nuts in the hex recesses of the high-voltage top cover and strain relief. There are two of these in either part. You know the drill by now.

• Mount the top and bottom high-voltage covers to the support board using two screws. There should only be one way to do this.

• Mount the strain relief to the bottom high-voltage cover.

• Place the support board onto the main assembly, making sure to align the screw holes. The upright flanges inside the support board interface part should constrain it.

• Place the support board cover on top. Again, some "gentle persuasion" may be needed for the SMA connector insert the first time. Finally, clamp it down with four screws, that should mate with the four nuts in the support board interface part.

• Carefully lift the clock up by the wall mount. Make sure it's strong enough to hold the weight with ease.

• Find a nice place to mount it to a wall! You can just use a nail or screw to do it, or you could print a part that mates with the wall mount bracket if you're worried about the strength of the part.

Disassemble in the reverse order as usual. The wall mount can stay mounted to its quarter panel, but note that you can't remove the quarter panels from the acrylic without removing the support board assembly, because it hides one of the fourteen screws that mate with the acylic.

5) Electronic assembly

Some preprocessing is required:

• The 3D-printed parts include a small lead bending tool for the 3mm LEDs. It consists of two square printed parts, and is completed using four M3 nuts and four M3x12 screws. To use it, push the LED into the hole, bend the leads outward far enough for the screws to reach the recesses for the nuts on the other side, then carefully tighten the screws while guiding the leads into the cutouts for them. Once tightened, cut the exposed part of the leads off with pliers. Finally, disassemble everything again to retrieve the LED. I've found that two screws on opposite sides is enough.

• The trace connecting the USB bus voltage to the 5V rail on the Teensy LC must be cut, to prevent the power supply on the support board from trying to power your PC.

• The mainboard to support board connectors are slightly too short right out of the box: the male side should be soldered flush to the opposite side of the PCB rather than having it stick through slightly as usual.

Ultimately, the order in which you solder the parts is up to you. Here's some tips and recommendations, however.

• I couldn't be bothered to add part designators to the board generation scripts and design entry file formats, so you'll have to use the *.*.traces.png output files to figure out what to solder where. However, the circuitry is so repetitive that you won't need it most of the time.

• The mainboard circuitry is highly linear, which means you can solder one or a few subcircuits at a time and then test whether everything works. Start with the reset circuit and the clock pulldown resistor (the 10k resistor near the TSSOP I/O expander), then work your way around clockwise for the dividers, and finally solder the decoders. You can test using the staggered receptable for a standard 2.54mm 5-pin header (push it in upside-down; the spring force of the pins will friction-lock it in place). The f50Hz signal should receive a 0V..5V clock signal, Vled and Vffled should be pulled down to somewhere between 2.5V (max brightness) and 4.5V (least brightness) to turn the LEDs on, and 0V/5V should be self-explanatory. A two-channel waveform generator is ideal for the f50Hz and Vled/Vffled signals, the latter because a waveform generator can pull down as well (unless you have a super-fancy power supply, it won't be able to). If you don't have a waveform generator or only have a single-channel generator however, you can probably get the LEDs to light up with a 1:1 voltage divider using 100R resistors as well, and you can strobe the clock by just pushing a 5V wire into the f50Hz signal (it will bounce though, so this won't be very controlled). Use a properly current-limited power supply (somewhere around 400mA should be enough for the whole clock with the default LEDs), such that you don't fry something if you accidentally short-circuited something. Being able to see the current is also very useful, because then you'll see the current rise when a gate output is shorted. Other than that, ensure that all LEDs blink when you apply enough clock pulses. Some common symptoms:

  • Current shoots up by about 40mA for some flipflop states: there's probably a short-circuit to 0V or 5V after a 100R filter resistor.

  • Current shoorts up by about 150-200mA for some flipflop states: there's probably a short-circuit to 0V or 5V between a gate output and the 100R filter resistor.

  • Current limit kicks in at around 1.0V to 1.5V: you probably mounted a gate rotated 180-degrees.

  • Current limit kicks in immediately: you have a dead short somewhere. You can trace this by measuring the voltage across the decoupling capacitors while the power supply is on. I got about 2.7mV over the decoupling capacitors serving good circuits and less than 2mV for the one that had the short, for only 200mA supply current.

  • No unexpected current (the current should be <1mA when the f50Hz input is idle and the LEDs are off), but one or more flipflops/decoder outputs don't work right: usually this is due to a bad soldering joint for one of the gates. You'll have to debug this by finding the gate that doesn't perform its logic function properly.

  • The circuit works, but a LED doesn't light up: check for bad soldering joints in the LED circuitry.

  • Everything is fine in steady-state, but a flipflop doesn't work: I didn't personally encounter this, but this is what I'd expect to see if you misplaced a capacitor or resistor somewhere in the RC filter circuits. The filters are there to solve worst-case hold timing, so the flipflops might misbehave with improper filters. I've found that leaving the 330pF and 2.2nF capacitors out entirely also works, however (with a sample size of only 1 flipflop, though).

• While soldering the mainboard, put short screws in the screw holes that prevent you from accidentally exerting force on the 3mm LEDs or 1.27mm jumpers when the board is upside-down. Otherwise, you can easily bend the headers, or push the SMD pads for the LEDs right off the board.

• For the support board, first solder the hot-swap controller circuit and test it. There's a lot of critical resistor values there, and if they're wrong, the board won't do anything or won't be as protected against over/undervoltage and overcurrent as it can be. I would furthermore suggest leaving the mains stuff for last, because it's large, and because you'll then lose the ability to power the board with a better-protected lab power supply.