Instructions EASY-ROTOR-CONTROL 3D V1.2_1

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Rudolf Gallagher
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1 Congratulations for buying your EASY-ROTOR-CONTROL 3D (shortly ERC-3D). This document will guide you through the needed steps for assembly, configuration and installation of the ERC-3D. You will reach the best result by following these instructions step by step. Table of contents Safety Bill of Material (BOM) Assembly of RS232 cable Assembly of the Controller PCB Connection of the DC-supply and check of the voltage-regulator Assembly of the LED-PCB Assembly of the flat-ribbon-cable Installation of the Service Tool Connect the ERC-3D to the PC Configuration of the Service Tool Configuration of the COM-Port Read the ERC-3D-configuration-parameters Language Other functions of the Service Tool Installation of the ERC-3D Theory of operation Calibration First check of calibration with Rotor-Control 3D First check of calibration with PstRotator-Lite Connect the ERC-3D to other programs Optional LCD-display Assembly of the flat-ribbon-cable Finalize the LCD-Display Tannenstr. 16 Page 1 of 20 erc@schmidt-alba.de

2 Safety- Don t continue using the product if fit is damaged. Keep electronic assemblies and components away from children! Products that carry electric voltages must be handled by taking care about the valid instructions and regulations. If the product must be repaired, only use original spare parts! Using different parts may cause property damage and personal injury! The repair has only to be done by an expert! Before applying main-voltage the product must be securely build into a housing to provide protection against accidental contact! The installation has to be done by a skilled expert. Cables that carry dangerous voltages (e.g. main-voltage) must be installed according to the valid instructions and regulations. The needed safety-distances have to be maintained. Connection-cables have to be chosen according to the needed diameter. Before working on the product all supply-voltages have to be securely cut of. The product is designed to work in clean and dry areas inside buildings. Prevent the product of humidity, water and heat. Don t use the product in areas where explosive gases, vapour or dust are or may occur. Don t let the product fall or apply mechanical stress as the product may be damaged. 1. Bill of Material (BOM) The Bom is in the order how you should use the parts. ERC3D V1.2 Bill Of Material QTY Type Value Pitch(mm) Reference Comments RS232-Cable 0,5 Cabel with Phonejack 3.5mm Stereo 2.5m for RS232 Adapter 1 DSUB-Connector 9 pol. Female for RS232 Adapter 1 DSUB-Case for 9 pol. for RS232 Adapter Controller-PCB Assembly 1 PCB 2-layer 107x65mm V Capacitor ceramic 100n 50V 20% 2.5 C3,C5,C12-C19 1 Crystal MHz HC49U Q1 2 IC-Socket 16 pol. DIL16 IC2*,IC4* for IC2 1 IC-Socket 28 pol. DIL28 IC1* for IC1 2 Capacitor ceramic 22p 16V 5% 2.5 C1,C2 alt. 27p 1 Phone-Jack 3.5mm Stereo X2 RS232 6 Capacitor Tantal 1u 35V 20% 2.5 C6,C7,C8,C9,C10,C11 1 Mini-Fuse 1.0A 5 F1 1 Resistor 2.7K 5% 2.5 R16 Tannenstr. 16 Page 2 of 20 erc@schmidt-alba.de

3 1 Resistor 10K 5% 2.5 R1 4 Resistor 15K 5% 2.5 R7,R8,R11,R12 2 Resistor 33K 5% 2.5 R6,R13 2 Resistor 220K 5% 2.5 R5,R14 0 Resistor not assembled R15 4 Diode BAT D6,D7,D10,D11 alt.: BAT42 2 Diode P6KE33CA 3.81 D5,D12 1 Diode 1N D1 alt.: 1N Coil 10u 10% SMCC 2.5 L1,L2,L3 2 Pinheader 2x5 pol JP1,JP2 1 Connector 2 pol. 5mm 5 X4 9 Connector 3 pol. 5mm 5 X3,X5,X6-X9,X10-X12 1 DC-Jack 2.1/5.5mm X1 DC 1 Capacitor Al 100u 16V 20% 2.5 C4 1 Relay G6D-1A-ASI12VDC K3 4 Relais FTR F1CA012V K1,K2,K4,K5 alt.: LMR2-12D 1 Voltage-Regulator 7805 TO220 IC3 Mechanical Assembly and ICs on socket 1 IC MEGA168(P)-20PU DIL28 IC1 with socket 1 IC MAX232CPE DIL16 IC2 with socket 1 IC ULN2003AN DIL16 IC4 with socket 4 Distance-Bolt M3x8x6mm 8 Spring-Wascher 3.2mm 4 Nuts M3 4 Screw M3x6mm 1 DC-Connector 2.1/5.5/9mm for DC 3 Cable-Ties 150mm 2 Cable blue 1m 0.75sqmm for installation 2 Cable black 1m 0.75sqmm for installation LED PCB Assembly 1 PCB 2-layer 10x65mm V1.0 5 Resistor 1K 5% 2.5 R2,R3,R4,R9,R10 2 LED yellow 3mm LC 2.5 LED3,LED5 2 LED green 3mm LC 2.5 LED2,LED4 1 LED red 3mm LC 2.5 LED1 1 Pinheader 2x5 pol JP3 2 Distance-Bolt M3x8x6mm 2 Spring-Wascher 3.2mm 2 Nuts M3 2 Screw M3x6mm 0,2 Flat ribbon cable 1m 10 pol Connector 2x5 pol for flat ribbon cable Tannenstr. 16 Page 3 of 20 erc@schmidt-alba.de

be measured which of the inner cables is connected to what contact of the phone-jack. Alternatively to the 3-wire cable a 2-wire cable with shielding can be delivered.

4 2. Assembly of RS232 cable Materials needed: - Cable with 3.5mm Stereo phone-jack - DSUB-connector 9 pole female - DSUB-case for 9 pole Pinning of DSUB seen from the connector-frontside As the delivered cables differ with their colours, it has to be measured which of the inner cables is connected to what contact of the phone-jack. Alternatively to the 3-wire cable a 2-wire cable with shielding can be delivered. For this kind of cables the both shielding have to be twisted together. The shielding is representing GND. GND: inner contact of the phone-jack : to PIN 5 of the D-SUB RXD: middle contact of the phone-jack : to PIN 2 of the DSUB TXD: tip-contact of the phone-jack : to PIN 3 of the DSUB Tannenstr. 16 Page 4 of 20 erc@schmidt-alba.de

Dismantle the outer isolation of the cable by 25mm.

For 2-wire cables, drill the 2 shielding wires together.

of the outer isolation, that you removed in the last

5 Dismantle the outer isolation of the cable by 25mm. Dismantle the inner cables by 2mm. For 2-wire cables, drill the 2 shielding wires together. Solder the Cable to the DSUB-connector respecting the colours measured in the last step. - RXD to Pin 2 - TXD to Pin 3 - GND to Pin 5 Put a part of the outer isolation, that you removed in the last step, below the cord grip to fully secure the cable from slipping. Tannenstr. 16 Page 5 of 20 erc@schmidt-alba.de

6 3. Assembly of the Controller PCB Assemble and solder the components according to the following drawings. Please read the following instructions before you start : 1. The vertical assembled Diodes and the crystal should have a distance (1-2mm) to the PCB while soldering. Otherwise there is the risk of overheating these components while soldering. 2. Put the 3-pin connectors X3/X12, X5/X10, X8/X11 together before assembly. You will get 3 pieces of 6-pin connectors. 2. Take care of polarization of the following components : - Diodes D1,D6,D7,D10,D11 (D5,D12 are bidirectional, no polarization) - AL-Capacitor C4 - Tantal-Capacitors C6,C7,C8,C9,C10,C11 - Voltage Regulator IC3 - IC-Sockets IC1*,IC2*,IC3* - Connectors X3,X4,X5,X6,X7,X8,X9,X10,X11,X12 (cable entry to the outside) Those components are marked red in the following drawing. Components : Colour-code of Resistors : 1K 5% alt.: 1K 1% 2K7 5% alt.: 2K7 1% 10K 5% alt.: 10K 1% 20K 5% alt.: 20K 1% 39K 5% alt.: 39K 1% 220K 5% alt.: 220K 1% brown-black-red-gold brown-black-black-brown-brown red-violett-red-gold red-violett-black-brown-brown brown-black-orange-gold brown-black-black-red-brown red-black-orange-gold red-black-black-red- brown orange-white-orange-gold orange-white- black-red-brown rot-rot-yellow-gold rot-rot- black-orange-brown Colour-code of Coils: 10uH 10% brown-black-black-silver Diodes : ICs and sockets = Tannenstr. 16 Page 6 of 20 erc@schmidt-alba.de

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9 After assembly, attach the 4 bolts with nuts for mounting. Use spring-washers below the nuts. Check carefully the assembly. So, this is how it should look like. So fare, don t put the ICs (MEGA168, MAX232 and ULN2003) into their sockets. First a little electrical test should be performed: Tannenstr. 16 Page 9 of 20 erc@schmidt-alba.de

4. Connection of the DC-supply and check of the voltage-regulator After checking all assembled components for identity, polarization and solder-bridges, connect 10 to 15VDC to connector X1.

Connect the Plus(+)-pole to the center contact and the Minus(-)-pole to the outer contact. If DC is reversed, nothing will happen as the Circuit is proven against wrong polarization.

10 4. Connection of the DC-supply and check of the voltage-regulator After checking all assembled components for identity, polarization and solder-bridges, connect 10 to 15VDC to connector X1. This can be done by using the DC-Connector supplied with the kit or any other DC-Source with a appropriate DC-Connector of 2.1/5.5mm and Plus(+) on the center-pin. Connect the Plus(+)-pole to the center contact and the Minus(-)-pole to the outer contact. If DC is reversed, nothing will happen as the Circuit is proven against wrong polarization. After connecting DC correctly, you should measure +5VDC +/-0.2V at the testpoint TP. Disconnect the supply now The pins of the ICs have to bend before you can put them into their sockets. Use a hard base (e.g. your working desk) and bend the row of pins slightly, that they get an angle of 90. Take care of the direction of the components and not to bend any pins while inserting the components into the sockets. Testpoint TP : +5V Tannenstr. 16 Page 10 of 20 erc@schmidt-alba.de

5. Assembly of the LED-PCB Assemble and solder the components according to the following drawings. Please read the following instructions before you start : 1.

Assembly of components - The orientation of the PCB can be figured out by the marking of pin 1 of the connector on the top-surface of the PCB.

11 5. Assembly of the LED-PCB Assemble and solder the components according to the following drawings. Please read the following instructions before you start : 1. Take care of polarization of the following components : - LED1-LED5 Those components are marked red in the following drawing. 2. Assembly of components - The orientation of the PCB can be figured out by the marking of pin 1 of the connector on the top-surface of the PCB. - Before assembly, attach the 2 bolts with nuts for mounting. Use spring-washers below the nuts. - The LEDs will be assembled on the bottom-side of the PCB - The connector and 1K resistors will be assembled on the top-side of the PCB - The height of the LEDs over the PCB should be 11mm. This distance can be achieved by putting the screws into the bolts while soldering the LEDs. 11mm Components: LED : = = long leg Check carefully the assembly. So, this is how it should look like. Tannenstr. 16 Page 11 of 20 erc@schmidt-alba.de

6. Assembly of the flat-ribbon-cable Needed material : - Flat-ribbon-cable 20cm - 2 pieces of 2x5 pin connectors with strain relief Steps : - cut the flat-ribbon-cable if you need a different length

put the strain relief on top. Now connect the LED-PCB to the 2x5 pinheader JP2 on the Controller-PCB by using the flat-ribboncable. Don t use JP1 as this pinheader is for an optional LCD-display.

12 6. Assembly of the flat-ribbon-cable Needed material : - Flat-ribbon-cable 20cm - 2 pieces of 2x5 pin connectors with strain relief Steps : - cut the flat-ribbon-cable if you need a different length - position the connectors as shown in the following picture: - Press the connectors by using a pliers or a vice unless they snap in - Bend the flat-ribbon-cable once on the top of the connector and put the strain relief on top. Now connect the LED-PCB to the 2x5 pinheader JP2 on the Controller-PCB by using the flat-ribboncable. Don t use JP1 as this pinheader is for an optional LCD-display. The red marked side of the flatribbon-cable has to align with the pin 1 of the pinheaders. The marking of pin 1 on the LED-PCB and the Controller-PCB is visible on the top-surface of the PCBs. This is how it sould look like: Tannenstr. 16 Page 12 of 20 erc@schmidt-alba.de

7. Installation of the Service Tool The Service Tool is on the CD supplied with the kit. Start the Setup-File SETUP ERC-3D_Vnn.EXE directly on the CD and follow the instructions.

13 7. Installation of the Service Tool The Service Tool is on the CD supplied with the kit. Start the Setup-File SETUP ERC-3D_Vnn.EXE directly on the CD and follow the instructions. The installation wizard will automatically install the Service Tool in the program directory (or any other if you choose a different one) and put an icon on your desktop. 8. Connect the ERC-3D to the PC Connect the ERC-3D to one of the COM-Ports using the RS232-cable from the kit. If you don t have a (free) COM-Port on your computer you may use an additional USB-serial-converter to connect to the USB-Port of your computer. Now connect the ERC-3D to a DC-Source of 10 to 15 VDC. 9. Configuration of the Service Tool Start the Service Tool by double-clicking the Icon on the desktop. Tannenstr. 16 Page 13 of 20 erc@schmidt-alba.de

9.1 Configuration of the COM-Port On shipment, the Service Tool is most probably not configured to the comport, wehere you connected the ERC-3D, hence after Start-Up the program may bring up an

14 9.1 Configuration of the COM-Port On shipment, the Service Tool is most probably not configured to the comport, wehere you connected the ERC-3D, hence after Start-Up the program may bring up an error-message because of the wrong COM-Port. Choose the right COM-Port. The Service Tool will check the availability of the ERC-3D at the choosen COM-Port. If successfull, the Service Tool will read the configuration-parameters of the ERC-3D and populates the ERCconfiguration-window and the ERC-calibration-window. You can now perform a little hardware-test before the installation. Click the -button and all relays will be switched on sequentially. This test-function can be stopped by removing the ERC-3D from the DC-supply. 9.2 Read the ERC-3D-configuration-parameters The parameters of the ERC-3D can be read by clicking the button. 9.3 Language The Service-Tool and the help-files are available in different languages. Choose the language with the -box. Tannenstr. 16 Page 14 of 20 erc@schmidt-alba.de

15 9.4 Other functions of the Service Tool The other functions of the Service Tool are well described in the help-function of the Service Tool. Click the button. 10. Installation of the ERC-3D Easy-Rotor-Control can either be installed in the rotor-controllers housing or in certain cases it can be connected completey from the outside to the rotor-controller. The installation is specific for every type of rotator or controller. Therefore you received an specific instruction, how to install the ERC-3D in your setup Theory of operation A Microcontroller receives commands via the RS232-interface in the Yaesu GD232B protocol from the programs that support controlling rotators. These commands include the target-position for the rotators (Azimuth and Elevation ) or a rotor-stop-command or the request to report the current position of the antenna. The ERC-3D takes the task to move the rotator to the desired position or, to stop the rotator while it is already moving. Also changes of the direction are possible while the rotator is moving. The current position of the rotators is calculated by the ERC-3D from the measured rotor-feedback-voltages AZ and EL. To achieve accurate function, the ERC-3D has to be calibrated to the specific value of the rotor-feedback-voltages. (ref. To the next chapter) Depending on the direction to move, the relays at contacts CW and CCW or UP and DWN are closed. With a programmable delay the relay at contacts AUX will be activated to release a brake prior to movement or to attach the brake after the rotator has stopped.. The RS232-connector ist a 3.5mm phonejack which will provide a standard 9-pin DSUB connector together with the adapter-cable made in chapter 2. The power supply connector is a standard DC-jack with an inner contact with diameter 2.1mm and an outer diameter of 5.5mm. 11. Calibration After the ERC-3D is connected to the rotor-controller, it has to be calibrated. This calibration is needed, because different kind of rotators deliver different kind of feedback-voltages. Also variations between rotators of the same model would lead to inaccuracy. To calibrate the ERC-3D, it has to meassure the rotor-feedback-voltages at both ends and possible overlaps (turning radius > 360 ). The calibration is a software-guided procedure, which will be started by pressing the the service tool. Just follow the instructions given. button of 12. First check of calibration with Rotor-Control 3D The rotor-control-program Rotor-Control 3D is on the CD supplied with the kit. Start the Setup-File SETUP RC-3D_Vnn.EXE directly on the CD and follow the instructions. Tannenstr. 16 Page 15 of 20 erc@schmidt-alba.de

The installation wizard will automatically install the Service Tool in the program directory (or any other if you choose a different one) and put an icon on your desktop.

16 The installation wizard will automatically install the Service Tool in the program directory (or any other if you choose a different one) and put an icon on your desktop. Start Rotor-Control 3D by double-clicking the Icon on the desktop. The green pointers and numbers show the current position of the rotators. Targets can be put at the red numbers. You can control the rotators for Azimuth and Elevation separately or together. Click the GO- or STOPbuttons. You can also move a rotator to a target-position by clicking on any point of the graphics. By clicking the button PARK, the rotators move to their configured parking positions. 13. First check of calibration with PstRotator-Lite On the CD you will find a Lite-version of the professional rotor-control-program PstRotator by YO3DMU. Instal the program by starting the setup-file PstRotatorAZEL_Lite in the directory PstRotator Lite der CD. Close the Service-Tool before you start PstRotator as they cannot share the same COM-port. Tannenstr. 16 Page 16 of 20 erc@schmidt-alba.de

14. Connect the ERC-3D to other programs Please take care about the following points, if you want to control your ERC-3D with other programs : - Choose the right COM-port - Adjust the

17 14. Connect the ERC-3D to other programs Please take care about the following points, if you want to control your ERC-3D with other programs : - Choose the right COM-port - Adjust the comport in the program to : 9600 N81 o 9600 Baud o No Parity o 8 databits o 1 stopbit - Use the protocol Yaesu GS232B or GS232A Tannenstr. 16 Page 17 of 20 erc@schmidt-alba.de

15. Optional LCD-display LCD Assembly 1 LCD-Display 16x2 0,2 Flat ribbon cable 1m 10 pol. 1.27 1 Connector 2x5 pol. 2.54 for flat ribbon cable 2 Resistor 27R 5% 4 Distance-Bolt M3x8x6mm 4 Spring-Wascher 3.

18 15. Optional LCD-display LCD Assembly 1 LCD-Display 16x2 0,2 Flat ribbon cable 1m 10 pol Connector 2x5 pol for flat ribbon cable 2 Resistor 27R 5% 4 Distance-Bolt M3x8x6mm 4 Spring-Wascher 3.2mm 4 Nuts M3 4 Screw M3x6mm Assembly of the flat-ribbon-cable Needed material : - Flat-ribbon-cable 20cm - 2x5 pin connector with strain relief Steps : - cut the flat-ribbon-cable if you need a different length - position the connector as shown in the following picture: - Press the connector by using a pliers or a vice unless it snaps in - Bend the flat-ribbon-cable once on the top of the connector and put the strain relief on top Finalize the LCD-Display Solder the 2 pieces of 27R resistors for the LCD-Backlight to the LCD-display according to the following pictures. 1x 27R on the bottom-side of the LCD between Pin 2 und Pin 15 1x 27R on the top-side of the LCD between Pin 1 und Pin 16 Tannenstr. 16 Page 18 of 20 erc@schmidt-alba.de

Take care not to make any shortages with the legs of the resistors Splice the 10 wires

Solder the 10 wires to the display as shown (take care about the red marking of the

The red marked side of the flat-ribbon-cable has to align with the pin 1 of the

19 Take care not to make any shortages with the legs of the resistors Splice the 10 wires of the flat-ribbon-cable by 5cm. Dismantle the 10 wires and pre-solder them. Solder the 10 wires to the display as shown (take care about the red marking of the flat-ribbon-cable). After soldering attach the 4 bolts with nuts for mounting. Use spring-washers below the bolts. Now connect the flat-ribbon-cable to the 2x5 pinheader JP1 on the Controller-PCB. The red marked side of the flat-ribbon-cable has to align with the pin 1 of the pinheader. The marking of pin 1 on the Controller-PCB is visible on the top-surface of the PCB. This is how it should look like: Tannenstr. 16 Page 19 of 20 erc@schmidt-alba.de

AUX CW CCW UP DOWN The LCD is showing the current directions for Azimuth (AZ) and Elevation (EL), the target directions and the directions when moving.

20 AUX CW CCW UP DOWN The LCD is showing the current directions for Azimuth (AZ) and Elevation (EL), the target directions and the directions when moving. Below the LCD you see the LED-PCB indicating the relays that are switched for these movements. Tannenstr. 16 Page 20 of 20 erc@schmidt-alba.de

Desktop housing AZ/EL Kit V1.2 for ERC-M Instructions. Instructions

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