EASY-ROTOR-CONTROL M V2.2 Instructions

EASY-ROTOR-CONTROL M V2.2 Instructions

___________________________________________________________________________ © Ing.-Büro E. Alba de Schmidt web : www.schmidt-alba.de Tannenstr. 16 Page 1 of 44 email : [email protected] 86836 Untermeitingen / Germany This document is for the user only. Any publishing (printed or in electronic form) is not allowed.

Instructions

Congratulations for buying your EASY-ROTOR-CONTROL M (shortly ERC-M). This document will guide you through the needed steps for assembly and configuration of the ERC-M. You will reach the best result by following these instructions step by step.

Table of contents

Safety-Instructions ................................................................................................................. 2

1. ERC-M USB ...................................................................................................................... 3

1.1 Bill of material (BOM)................................................................................................. 3

1.2 Preparation of USB-modul........................................................................................... 4

1.3 Assembly of the ERC-M USB PCB............................................................................. 4

1.4 Connection of the DC-supply and check of the voltage-regulator............................... 8

1.5 Insert ICs and the USB-module ................................................................................... 9

1.6 Establishing the USB-connection................................................................................. 9

2. ERC-M RS232 ................................................................................................................. 10

2.1 Bill of material (BOM)............................................................................................... 10

2.2 Assembly of RS232 cable .......................................................................................... 11

2.3 Assembly of the ERC-M RS232 PCB........................................................................ 12

2.4 Connection of the DC-supply and check of the voltage-regulator............................. 16

2.5 Insert ICs .................................................................................................................... 17

3. LAN-Interface (optional) ................................................................................................. 18

3.1 Bill of material ........................................................................................................... 18

3.2 Assembly of the LAN-Interface ................................................................................. 18

3.4 Check of the DC/DC-converter.................................................................................. 20

3.5 Device-Installer .......................................................................................................... 21

3.6 Installation of the COM-Port-Redirector (CPR) ........................................................ 21

4. Rotor-Card (optional) ....................................................................................................... 23

4.1 Bill of material ........................................................................................................... 23

4.2 Assembly of the Rotor-Card PCB.............................................................................. 23

4.3 Connection of the Rotor-Card .................................................................................... 25

4.4 Test of Rotor-Card ..................................................................................................... 26

4.5 Installation of the Rotor-Card into a control-box....................................................... 26

5. SlimLine housing (optional)............................................................................................. 28

6. HID AZ/AZ or AZ/EL and desktop housing (optional)................................................... 29

6.1 Bill of material ........................................................................................................... 29

6.2 Assembly of bottom-side HID-PCB .......................................................................... 30

6.3 Assembly of top-side HID-PCB AZ/AZ (dual azimuth) ........................................... 31

6.4 Assembly of top-side HID-PCB AZ/EL (azimuth&elevation) .................................. 33

6.5 Cable to connect the HID to ERC-M ......................................................................... 35

6.6 Cable to connect the ERC-M to rear-side D-SUB ..................................................... 35

6.7 Mechanical integration into the desktop-housing ...................................................... 36

7. The Service-Tool.............................................................................................................. 38

7.1 Configuration of the COM-Port ................................................................................. 38



7.2 Read the ERC-M-configuration-parameters .............................................................. 38

7.3 Language .................................................................................................................... 38

7.4 Other functions of the Service Tool ........................................................................... 38

8. Theory of operation .......................................................................................................... 39

9. Calibration........................................................................................................................ 39

10. First check of calibration with Rotor-Control M ........................................................... 39

11. Connect the ERC-M to other programs.......................................................................... 40

Appendix .............................................................................................................................. 41

Appendix1: Pin-out of D-SUB15 ERC-M ....................................................................... 41

Appendix2: Pin-out of mini-DIN rotor-card .................................................................... 41

Appendix3: Connection of rotor-card to ERC-M ............................................................ 41

Appendix4: Pin-out of the HID-connector on ERC-M .................................................... 42

Appendix5: Schematics Rotor-Card................................................................................. 42

Appendix6: Schematics ERC-M ...................................................................................... 43

Appendix7: Schematics HID............................................................................................ 44

Safety-Instructions

• Don’t continue using the product if it 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!

• The installation has to be done by a skilled expert.

• 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. ERC-M USB

If your kit is RS232 (not USB) go to chapter 2.

1.1 Bill of material (BOM) The BOM is in the order how you should use the parts.

ERC-M USB V2.2 Bill Of Material

QTY Type Value Reference Comments

1 USB-module FTDI IC3

1 Pinheader 1x8 pole precision for USB-Module

1 PCB ERC-M 2-layer 80x65mm V2.2

9 Capacitor ceramic 100n 50V 20% C3,C4,C6,C9,C10, C11,C12,C13,C14

1 Capacitor ceramic 10n 50V 20% C21

1 Crystal 9.8304 MHz HC49U Q1

2 IC-socket 16 pole DIL16 for IC2,IC3

1 IC-socket 28 pole DIL28 for IC1

2 Capacitor ceramic 22p 16V 5% C1,C2

2 Capacitor tantal 1u 35V 20% C7,C8

1 Mini-fuse 1.0A F1

2 Transistor BC557 T1,T2 alt. BC558,BC559

1 Voltage-regulator 78L05 TO92 IC4

2 Resistor 4K7 5% R10,R11 alt. 4K7 1%

4 Resistor 20K 5% R2,R3,R6,R7 alt. 20K 1%

2 Resistor 39K 5% R4,R8 alt. 39K 1%


4 Coil 10u 10% SMCC L1,L2,L3,L4

8 Diode BAT48 D2,D3,D4,D5,D6, D8,D9,D10

3 Diode 1N4004 D1,D11,D13 alt. 1N4007

1 Diode ZD2.7 D14

1 Box-header 2x8 pole X3

1 Pinheader 1x2 pole JP1

1 DC-Jack 2.1/5.5mm J1

1 Capacitor electrolytic 100u 16V 20% C5

1 USB-jack Type B X2

1 DSUB-connector 15 pole female print X1

1 DC-Connector 2.1/5.5/9mm for DC-cable

1 DSUB-connector 15 pole male solder for rotor-Cable

1 DSUB-case for 15 pole for rotor-Cable

1 USB-cable A to B 1.8m USB-cable

1 IC MEGA328P-20PU IC1

1 IC ULN2003AN IC2

1 Jumper blue for JP1 Power/Reset



1.2 Preparation of USB-modul

Solder the 8-pin pin-header 90° to the bottom side of the USB-module. Take care, that the shorter side of the pins is soldered to the USB-Module.

1.3 Assembly of the ERC-M USB PCB Assemble and solder the components according to the following drawings. Please read the following instructions before you start: 1. The vertical assembled Diodes should have a distance (1-2mm) to the PCB while soldering. Otherwise there is the risk of overheating these components while soldering. 2. Take care of polarization of the following components (marked red in the assembly drawing):

- Diodes D1,D2,D3,D4,D5,D6,D8,D9,D10,D11,D13,D14 - Capacitor electrolytic C5 - Capacitor tantal C7,C8 - IC-socket for IC1,IC2,IC3 - Transistor T1,T2 - Voltage-regulator IC4 - Box-header X3

3. Carefully compare the position of the PCB with the drawings before you start to assemble it. Components: Colour-code of Resistors: 4K7 5% yellow-violet-red-gold alt.: 4K7 1% yellow-violet-black-brown-brown 20K 5% red-black-orange-gold alt.: 20K 1% red - black-black-red- brown 39K 5% orange-white-orange-gold alt.: 33K 1% orange-white- black-red-brown 220K 5% rot-rot-yellow-gold alt.: 220K 1% rot-rot- black-orange-brown Colour-code of Coils: 10uH 10% brown-black-black-silver Diodes : ICs and sockets =



Not to be assembled components are marked grey in the assembly drawing.



USB-Module



Check carefully the assembly. So, this is how it should look like.



So fare, don’t put the ICs (MEGA328, USB-Module and ULN2003) into their sockets. First a little electrical test should be performed:

1.4 Connection of the DC-supply and check of the voltage-regulator Now put the jumper on the 1x2 pinheader JP1 (the jumper supplies the ERC with +5V). After checking all assembled components for identity, polarization and solder-bridges, prepare a DC-cable with 10 to 15VDC by using the DC-connector supplied with the kit or use any other DC-supply with that voltage and an appropriate DC-Connector of 2.1/5.5mm. Connect the Plus(+)-pole to the center contact and the Minus(-)-pole to the outer contact. Before connecting the DC-connector to the ERC-M, measure the voltage at the connector, if it is in the range needed. If DC is reversed, nothing will happen as the Circuit is proven against wrong polarization. Now plug the DC-connector into J1 of the ERC-M. After connecting DC correctly, you should measure +5VDC +/-0.2V at the test-point +5V and +10 to +15VDC at test-point +12V against GND. Disconnect the supply now. Testpoint +5V Testpoint +12V

GND



1.5 Insert ICs and the USB-module The pins of the ICs have to be 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°. Now insert the ICs and take care about direction of the components and not to bend any pins while inserting the components into the sockets. Also insert the USB-module on the socket of IC3 as shown.

1.6 Establishing the USB-connection Plug the USB-B-connector to the ERC-M and the USB-A-connector to a free USB-connector on your PC. Depending on your operating-system, you will be asked to install an USB-driver. This driver is available on the CD delivered with your kit. After successful installation of the driver, a new COM-Port (COMn) is available. You can identify the COM-port-number by inspecting the hardware-settings of your PC. In case you have a conflict with another COM-port (e.g. virtual COM-port), change the COM-port-number in the properties.



2. ERC-M RS232

If your kit is USB (not RS232) go to chapter 1.

2.1 Bill of material (BOM) The BOM is in the order how you should use the parts.

ERC-M RS232 V2.2 Bill Of Material


1 DSUB-connector 9 pole female solder for RS232-cable

1 DSUB-case for 9 pole for RS232-cable

1 Cable with Phone-Jack 3.5mm Stereo 1.25m for RS232-cable

1 PCB ERC-M 2-layer 80x65mm V2.2

10 Capacitor ceramic 100n 50V 20% C3,C4,C6,C9,C10,C11, C12,C13,C14,C22

1 Crystal 9.8304 MHz HC49U Q1

2 IC-socket 16 pole DIL16 for IC2, IC3

1 IC-socket 28 pole DIL28 for IC1

2 Capacitor ceramic 22p 16V 5% C1,C2

6 Capacitor tantal 1u 35V 20% C7,C8,C17,C18,C19,C20

1 Phone-Jack 3.5mm Stereo X10

1 Mini-fuse 1.0A F1

2 Transistor BC557 T1,T2 alt. BC558,BC559

1 Voltage-regulator 78L05 TO92 IC4

2 Resistor 4K7 5% R10,R11 alt. 4K7 1%

4 Resistor 20K 5% R2,R3,R6,R7 alt. 20K 1%



3 Coil 10u 10% SMCC L1,L2,L3

7 Diode BAT48 D2,D3,D4,D5,D6,D9,D10

3 Diode 1N4004 D1,D11,D13 alt. 1N4007

1 Diode ZD2.7 D14



1 DC-Jack 2.1/5.5mm J1

1 Capacitor electrolytic 100u 16V 20% C5

1 DSUB-connector 15 pole female print X1

1 DC-Connector 2.1/5.5/9mm for DC-cable

1 DSUB-connector 15 pole male solder for rotor-Cable

1 DSUB-case for 15 pole for rotor-Cable

1 IC MAX232 IC3

1 IC MEGA328P-20PU IC1

1 IC ULN2003AN IC2

1 Jumper blue for JP1 Power/Reset



2.2 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

NOTE: If you use the ERC-M in MASTER-SLAVE-mode over RS232, the pins for RXD and TXD must be crossed for the Master-ERC-M: TXD to Pin 2 and RXD to Pin3 of the D-SUB.



2.3 Assembly of the ERC-M RS232 PCB

Assemble and solder the components according to the following drawings. Please read the following instructions before you start: 1. The vertical assembled Diodes should have a distance (1-2mm) to the PCB while soldering. Otherwise there is the risk of overheating these components while soldering. 2. Take care of polarization of the following components (marked red in the assembly drawing):

- Diodes D1,D2,D3,D4,D5,D6,D9,D10,D11,D13,D14 - Capacitor Al C5 - Capacitor tantal C7,C8,C17,C18,C19,C20 - IC-socket for IC1,IC2,IC3 - Transistor T1,T2 - Voltage-regulator IC4 - Box-header X3

3. Carefully compare the position of the PCB with the drawings before you start to assemble it. Components : Colour-code of Resistors: 4K7 5% yellow-violet-red-gold alt.: 4K7 1% yellow-violet-black-brown-brown 20K 5% red-black-orange-gold alt.: 20K 1% red - black-black-red- brown 39K 5% orange-white-orange-gold alt.: 33K 1% orange-white- black-red-brown 220K 5% rot-rot-yellow-gold alt.: 220K 1% rot-rot- black-orange-brown Colour-code of Coils: 10uH 10% brown-black-black-silver Diodes : ICs and sockets = Not to be assembled components are marked grey in the assembly drawing. These components are for different interface options.










So fare, don’t put the ICs (MEGA328, MAX232 and ULN2003) into their sockets. First a little electrical test should be performed:

2.4 Connection of the DC-supply and check of the voltage-regulator Now put the jumper on the 1x2 pinheader JP1 (the jumper supplies the ERC with +5V). After checking all assembled components for identity, polarization and solder-bridges, prepare a DC-cable with 10 to 15VDC by using the DC-connector supplied with the kit or use any other DC-supply with that voltage and an appropriate DC-Connector of 2.1/5.5mm. Connect the Plus(+)-pole to the centre contact and the Minus(-)-pole to the outer contact. Before connecting the DC-connector to the ERC-M, measure the voltage at the connector, if it is in the range needed. If DC is reversed, nothing will happen as the Circuit is proven against wrong polarization. Now plug the DC-connector into J1 of the ERC-M. After connecting DC correctly, you should measure +5VDC +/-0.2V at the test-point +5V and +10 to +15VDC at test-point +12V against GND. Disconnect the supply now. Testpoint +5V Testpoint +12V

GND



2.5 Insert ICs 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°. Now insert the ICs and take care about direction of the components and not to bend any pins while inserting the components into the sockets.



3. LAN-Interface (optional)

3.1 Bill of material The BOM is in the order how you should use the parts.

ERC-M V2.0 LAN Bill Of Material


1 Diode 1N4004 D12 alt. 1N4007

2 Capacitor ceramic 100n 50V 20% C15,C16

1 Capacitor Tantal 1u 35V 20% C23


1 Diode BAT48 D7

1 XPORT 1001001-04R XP1 alt. 1001000-04R

1 DC/DC 12V 3.3V 1W DC1

1 Patchcable 2m Crossover

3.2 Assembly of the LAN-Interface

Assemble and solder the components according to the following drawings. The components to be assembled are marked blue in the following drawings. Please read the following instructions before you start: 1. The vertical assembled Diodes should have a distance (1-2mm) to the PCB while soldering. Otherwise there is the risk of overheating these components while soldering. 2. Take care of polarization of the following components :

- Diode D7,D12 - DC/DC DC1 - Capacitor tantal C23

Those components are marked red in the following drawing. It is important to solder the ground-lugs of the XPORT properly as they are used for heat-dissipation from the XPORT to the printed board. Components : Colour-code of Resistors: 10K 5% brown-black-orange-gold alt.: 10K 1% brown-black-black-red-brown Diodes : =





This is how it should look like:

3.4 Check of the DC/DC-converter After checking all assembled components for identity, polarization and solder-bridges, connect 10 to 15VDC to connector J1 as already performed in chapter 1.3. After connecting DC correctly, you should measure +3.3VDC +/-0.4V at the testpoint shown against GND. Testpoint : +3.3V

GND



3.5 Device-Installer The Device-Installer is needed to assign an IP-address to the LAN-Unit: The Device-Installer is available on the disk supplied with your ERC-M in the LANTRONIX-folder. You may find a newer version on the LANTRONIX homepage at www.lantronix.com. First connect the ERC-M with the cross-over patch-cable to your PC. Start the setup with the file: setup_di_x86x64cd_4.3.0.2.exe The unit’s IP address is normally set to 0.0.0.0 at the factory. The hardware address is on the product label. The unit is DHCP enabled as the default.

- Click Start – Programs – Lantronix – DeviceInstaller - DeviceInstaller. If your PC has more than one network adapter, a message displays. Select an adapter and click OK. Note: If the unit already has an IP address (e.g., DHCP has assigned an IP-address), click the Search icon and select the unit from the list of Lantronix device servers on the local network.

- Click the Assign IP icon . - If prompted, enter the hardware address (on the product label) in the format 00-20-4a-XX-XX-

XX, where the XXs are unique numbers/letters assigned to the product. Click Next. - Select Assign a specific IP address and click Next. - Enter the IP address. The Subnet mask displays automatically based on the IP-address; if

desired, you may change it. On a local network, you can leave the Default gateway blank (all zeros). Click Next.

- Click the Assign button and wait several seconds until a confirmation message displays. Click Finish.

- Select the XPort from the main window list and click Tools - Ping. The results display in the Status area. Click the Clear Status button to clear the window so you can ping the device again.

- Click the Close button. In case of any problems, disable the Windows-Firewall during the assignment of the IP-address and repeat the configuration.

3.6 Installation of the COM-Port-Redirector (CPR) The CPR is needed to redirect the LAN-device to a virtual-COM-port that can be accessed by the rotor-control-software. The following items are required to run CPR: - x86 (32bit): Windows XP, 2003 Server, Vista, 7, and 2008 Server - x64 (64bit): Windows Vista, 7, and 2008 Server - Microsoft .NET Framework v4.0. - 30MB free hard drive space. The "Internet Connection Firewall" must be disabled, or else UDP Ports 30718, 43282, 43283 must be available. Otherwise, you will not be able to detect or communicate with any devices on the network. To configure, go to the Control Panel, go to Network Settings, select the corresponding network adapter, choose Properties, and go to the Advanced tab. You may need to allow these ports access through the corporate firewall as well. The CPR-software is available on the disk supplied with your ERC-M in the LANTRONIX-folder. You may find a newer version on the LANTRONIX homepage at www.lantronix.com.



Start the setup with the file: setup_cpr_x86x64cd_4.3.0.0.exe You will find a quick-start-guide for CPR in the LANTRONIX-folder on the CD: Com-Port-Redirector_QS.PDF By default, the serial speed of the LAN-device is set to 9600 Baud. If you want to use it with a different speed, as your application doesn’t support 9600 Baud, change the speed settings with the Web-interface available through the CRP-software. As the LAN-device only supports 1 configured speed, it cannot be used with the Service-Tool to

- change speed of communication - perform a firmware-update

These actions are only available through the primary interface (USB, RS232).



4. Rotor-Card (optional)


Rotor-card V1.6 Bill Of Material


1 PCB RC 2-layer 67.5x43.6mm V1.6

1 Capacitor ceramic 100n 50V 20% C1

3 Diode 1N4004 D1,D2,D3 alt. 1N4007

1 Diode P6KE33CA D4

1 Coil 10u 10% SMCC L1

1 Terminal-block 2 pol. 5mm X6

5 Terminal-block 3 pol. 5mm X1,X2,X3,X4,X5

1 Connector Mini-DIN 6-pole print X7

3 Relay FTR F1CA012V K1,K2,K3 alt. LMR2-12D alt. RT424012

4 Spring-washer 3.2mm

4 Screw M3x8mm

2 Nut M3

2 Mounting-angle 11x10x7mm

1 Cable with 6-pole mini-DIN 1m To ERC-M

1 Cable black 0.5m 0.75sqmm for cableing

1 Cable blue 0.5m 0.75sqmm for cableing

3 Cable-tie 150mm for cableing

4.2 Assembly of the Rotor-Card PCB

Assemble and solder the components according to the following drawings. Please read the following instructions before you start: 1. The vertical assembled Diodes 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 2-pole terminal-block X6 and the 3-pole terminal block X2 together before assembly. You will get a 5-pole terminal-block.

Do the same with 2 of the 3-pole terminal-blocks for X1 and X3 to build a 6-pole terminal-block. 3. Take care of polarization of the following components :

- Diodes D1,D2,D3 (D4 is bidirectional, no polarization) - Terminal-blocks X1,X2,X3,X4,X5,X6 (cable entry to the outside)

Those components are marked red in the following drawing. Diodes : =



After assembly, attach the 2 mounting-angles with 2 screws and 2 nuts. Use spring-washers below the nuts.

5

5

4 6

3

2

1




4.3 Connection of the Rotor-Card The connection between Rotor-Card and ERC-M has to be done with the 6-pin Mini-DIN-cable supplied with the Rotor-Card-kit. The connections are shown in the next picture. Connect the pins with the same colour between the Mini-DIN-connector and the D-SUB-connector for axis 1 or axis 2. 1 or 2 rotators can be connected to ERC-M.

- In an AZ/EL-configuration connect AZ to axis 1 and EL to axis 2. - If you only use 1 rotator, use axis 1.

Connector of ERC-M seen from outside Connector of Rotor-Card seen from outside



Mini-DIN Rotor-Card Signal D-SUB ERC-M axis 1

D-SUB ERC-M axis 2

1 CW/UP 9 15

2 CCW/DOWN 2 7

3 AUX 11 13

4 Feedback-voltage 1 8

5 GND 10 14

6 DC-supply 12 12

4.4 Test of Rotor-Card The Rotor-Card should be electrically tested before you connect it to the rotator-control-box. Perform the test as follows:

- Connect the Rotor-Card to the ERC-M by use of the cable prepared in chapter 4.3 - Connect 12V DC to the DC-connector of the ERC-M. The Rotor-Cards cannot work without

the external DC-supply. - Measure the voltage between the test-points TP_GND und TP_+12V. You should measure

now the 12V. Also the polarity is very important. You should measure +12V at TP_+12V against TP-GND. If the polarity is wrong, the Mini-DIN-cable is wired wrong.

- Now connect the ERC-M to the PC and start the Service-Tool. - Press the Test-button of the Service-Tool. - The relays of the Rotor-Card(s) will now engage in the following sequence in steps of 1

second: CW 1 / CCW 1 / CW 2 / CCW 2 / AUX 1 / AUX 2

4.5 Installation of the Rotor-Card into a control-box Rotor-cards are to be mounted inside the control-boxes that don’t provide a remote connector. Therefore you need to drill 3 holes in the housing of the control-box according to this drawing:

V



all values in mm (milli-meter) First drill the centre-hole (10mm) and than the smaller holes. Take care, that the bottom-side of the rotor-card has at least a distance of 8mm to the housing. This is very important to keep the safety-distances, especially when the rotor- card is carrying main-voltage (e.g. the brake-circuit of a HAM-IV). Mount the rotor-card to the control-box using the 2 screws and spring-washers below the screws. The wiring of the rotor-card to the different control-boxes is shown in the Installation-Guide provided on the CD of your ERC-M-kit.



5. SlimLine housing (optional) Mount the front-panel to the aluminium-casting

Put the 4 rubber-feet to the bottom-side of the housing

Remove the 2 distance-bolts from the DSUB-connector on the ERC-M

Mount the back-panel to the ERC-M using the 2 bolts

Slide the ERC-M into the housing and mount the back-panel to the housing. READY

Pull the label from its foil and put it carefully on the top of the housing. Pay attention not to touch the sticky side of the label.



6. HID AZ/AZ or AZ/EL and desktop housing (optional) The HID is a human-interface-device and provides a 2x16 character LCD-display, 6 LEDs and 4 pushbuttons to the user. The HID and ERC-M is mounted in a powder-coated and silkscreen printed black sheet-metal-housing. The desktop-housing is available with different front-panels. One for AZ/AZ and one for AZ/EL operation. Beside the different housings, the top-side assembly of the HID-PCB for these 2 versions is different.


ERC-M V2.0 HID+Desktop-housing Bill Of Material


Assembly of bottom-side of PCB

1 PCB HID 2-layer 119.8x36.6mm V1.2

4 Diode 1N4004 D1,D2,D3,D4 Alt. 1N4148

6 Resistor 300R 5% R2,R3,R4,R5,R6,R7 Alt. 300R 1%

1 Resistor 54R 5% R8 Alt. 53.6R 1%

1 Potentiometer 10KA R1



Assembly of top-side of PCB

1 LCD with backlight DIS1

1 Pinheader 1x16 pole for LCD

4 Spacer 2.5x5x5mm LCD-mounting

4 Spring-washer 2.6mm LCD-mounting

4 Screw M2.5x12mm LCD-mounting

4 Nut M2.5 LCD-mounting

4 Switch 3FTL6 S5,S6,S7,S8

4 LED green 3mm LC LED5,LED6,LED7,LED8

2 LED yellow 3mm LC LED9,LED10

6 Spacer 3x12x4mm for LEDs

4 Dome 19mm for switches

Cableing

1 Flat ribbon cable 330mm 16 pol. for cables

2 Connector 2x8 pole for HID to ERC-M cable

1 DSUB-connector 15 pole male flat ribbon for D-SUB-cable

1 DSUB-connector 15 pole female flat ribbon for D-SUB-cable

1 DSUB mounting-kit UNC for D-SUB

Mechanical integration

1 Housing steel AZ/AZ or AZ/EL bottom and cover

4 Rubberfeet d=12mm for housing

8 Screw M3x6mm PCB-/HID-mounting

8 Screw 2.9mm x 6.5mm black for housing

1 Tool Allen-key 2.5mm for housing/rubberfeet



6.2 Assembly of bottom-side HID-PCB Assemble and solder the components according to the following drawings. Please read the following instructions before you start: Take care of polarization of the following components:

- Diodes D1,D2,D3,D4 - Box-header X2

Those components are marked red in the following drawing. Carefully compare the position of the PCB with the drawings before you start to assemble it. Components : Colour-code of Resistors: 54R 5% green-yellow-black-gold alt.: 53.6R 1% green-orange-blue-gold-brown 300R 5% orange-black-brown-gold alt.: 300R 1% orange-black-black-black-brown

This is how it should look like:

Inspect carefully the assembly and soldering. Once the LCD is mounted (next step), it becomes quite difficult to rework any soldering or assembly of the bottom-side !



6.3 Assembly of top-side HID-PCB AZ/AZ (dual azimuth) If your housing is AZ/EL (azimuth and elevation) proceed with step 6.4 First assemble the LCD with the 5mm spacers, screws, nuts and spring-washers to the PCB. Put the 16-pole pin-header between PCB and LCD before mounting. Leave the protection-foil on the LCD until the HID will be mounted into the housing. Now solder the 16-pole pin-header first to the LCD and than to the PCB. This is how it should look like:

Please read the following instructions before you proceed: LEDs:

Take care of polarization of the following components :

- LED5,LED6,LED7,LED8,LED9,LED10 Those components are marked red in the following drawing.

Assemble and solder the switches and LEDs according to the drawings. Take care that the switches fit plane to the PCB. Otherwise you will have problems with sticky switches later when the HID is mounted to the front-panel.

long leg

short leg flat side

round side

K



Hint: Only solder 1 leg of the switches and LEDs, check for alignment and than solder the remaining pins. Use the 3x12x4mm spacers for the LEDs to fix them in the right distance from the PCB.

Put the 19mm domes on top of the switches. This is how it should look like:

K

K

K K

K K



6.4 Assembly of top-side HID-PCB AZ/EL (azimuth&elevation)

If your housing is AZ/AZ (dual azimuth) go back to step 6.3 First assemble the LCD with the 5mm spacers, screws, nuts and spring-washers to the PCB. Put the 16-pole pin-header between PCB and LCD before mounting. Leave the protection-foil on the LCD until the HID will be mounted into the housing. Now solder the 16-pole pin-header first to the LCD and than to the PCB. This is how it should look like:

Please read the following instructions before you proceed: LEDs:

Take care of polarization of the following components :

- LED1,LED2,LED3,LED4,LED9,LED10 Those components are marked red in the following drawing.

Assemble and solder the switches and LEDs according to the following drawings. Take care that the switches fit plane to the PCB. Otherwise you will have problems with sticky switches later when the HID is mounted to the front-panel. Hint: Only solder 1 leg of the switches and LEDs, check for alignment and than solder the remaining pins.

long leg

short leg flat side

round side

K



Use the 3x12x4mm spacers for the LEDs to fix them in the right distance from the PCB.

Put the 19mm domes on top of the switches. This is how it should look like:

K

K

K

K

K

K



6.5 Cable to connect the HID to ERC-M

Cut 130mm from the flat-ribbon-cable and press the 2x8 pole connectors to both ends as shown in the next picture.

Take care of the orientation of the connectors (red circle) and the position of the red wire. Use a bench-vise to properly press the connectors to the flat-ribbon-cable. Those connectors are quite sensible and may damage if you don’t press them properly. Bend the flat-ribbon-cable on both ends over the top of the connector and put the strain-relief on.

6.6 Cable to connect the ERC-M to rear-side D-SUB

Take the remaining 200mm of the flat-ribbon-cable and remove 1 wire from the 16-pole cable to get a 15-pole cable (don’t remove the red wire, take the opposite site) Press the 2 DSUB-connectors to both ends as shown in the next picture. The red wire always has to show to pin 1 of the connectors. The pin-number of the connectors is printed in the plastics of the connectors.

Red wire on this side

Red wire on this side

Pin 1 Pin 1

male female



6.7 Mechanical integration into the desktop-housing Mount the 4 rubber-feet to the desktop housing using 4 screws 2.9x6.5mm.

Remove the protection-foil from the LCD and mount the HID into the desktop-housing with 4 Allen-screws using the Allen-tool provided with the kit.

Mount the ERC-M-PCB to the housing with Allen-screws.

Fold the 15-pole flat-ribbon-cable as shown and put the DSUB-connectors as shown and mount the female-DSUB-connector to the back-panel of the housing with the 2 UNC-distance-bolts and 2 washers from the DSUB-mounting kit.



Attach the 16-pole flat-ribbon-cable into the connectors as shown.

Connect the ERC-M to DC-supply or USB to check contrast settings. After start-up you should see a start-up-screen like this:

Adjust the contrast with the potentiometer R1 on the backside of the HID-PCB.

Put the top-cover onto the housing and fix it with 4 screws 2.9x6.5mm

Here we are: READY to go



7. The Service-Tool The Service Tool is on the CD supplied with the kit. Start the Setup-File SETUP ERC-M_Vnn.EXE (nn=version) 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. Start the Service Tool by double-clicking the Icon on the desktop.

7.1 Configuration of the COM-Port On shipment, the Service Tool is configured to COM1, which is most properly not the com-port, where you connected the ERC-M, 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-M at the chosen COM-Port. If successful, the Service Tool will read the configuration-parameters of the ERC-M and populates the configuration- and the calibration-windows.

You can now perform a little hardware-test before the installation. Click the -button and all LEDs on the HID-PCB and relays on the rotor-cards will be switched on sequentially.

7.2 Read the ERC-M-configuration-parameters

The parameters of the ERC-M can be read by clicking the button.

7.3 Language

The Service-Tool and the help-files are available in different languages. Choose the language with the

-box.

7.4 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.



8. Theory of operation

A Microcontroller receives commands via the RS232- or USB or LAN-interface in the Yaesu GS-232B (or GS-232A) or DCU-1 protocol from the programs that support controlling rotators.

The ERC-M takes the task to move the rotator to the desired position or to stop the rotator while it is moving. Also changes of the direction are possible while the rotator is moving. The current position of the rotators is calculated from the measured rotor-feedback-voltages AZ and EL. To achieve accurate function, the ERC-M 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 contacts CW and CCW or UP and DWN are tighten to ground. With a programmable delay the contact AUX1 and AUX2 will be activated to control the speed or the brake of the rotator.

The ERC-M is powered either the USB-bus, by the control-box it is connected to or by external 10..12VDC. The current consumption is according to the USB-specifications. Using an USB-hub may require to power this hub. Wherever there is a suitable DC-supply available on the rotor-controllers remote-jack, it is taken from there to supply the ERC-M. The ERC-M is than switching automatically to the external supply in order not to drawn current from the USB-bus.

9. Calibration After the ERC-M is connected to the rotor-controller, it has to be calibrated. This calibration is needed, because different kinds of rotators deliver different kinds of feedback-voltages. Also variations between rotators of the same model would lead to inaccuracy. To calibrate the ERC-M, it has to measure the rotor-feedback-voltages at both ends including overlaps (turning radius > 360°). The

calibration is a software-guided procedure, which will be started by pressing the or

button of the service tool. Just follow the instructions given by the calibration assistant. If the feedback-voltage of the rotator has unlineraities, an extended calibration can be performed every

30° for azimuth or every 15° for elevation by pressing the or button.

10. First check of calibration with Rotor-Control M The rotor-control-program Rotor-Control M is on the CD supplied with the kit. Start the Setup-File SETUP RC-M_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 puts an icon on your desktop. Set the ERC-M with the Service-Tool to Baudrate 9600 and Protocol GS232B. Start Rotor-Control M 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 STOP-buttons. 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.



Rotor-Control M can be configured to work for a single-axis setup or a dual-axis setup. AZ&EL AZ&AZ AZ only

11. Connect the ERC-M to other programs Please take care about the following issues, if you want to control your ERC-M with other programs :

- Choose the right COM-port - COM-port-speed in the program must be same as in ERC-M

o The speed of ERC-M is shown during the start-up on the LCD or in the service-tool - Adjust the comport in the program to : N-8-1 (No Parity, 8 databits,1 stopbit) - Use the same protocol in program and ERC-M (Yaesu GS232B, GS232A or Hygain DCU-1)

o The protocol of ERC-M is shown during the start-up on the LCD or in the service-tool



Appendix

Appendix1: Pin-out of D-SUB15 ERC-M Connector seen from outside to the female connector on ERC-M or on the back of the desktop-housing.

Appendix2: Pin-out of mini-DIN rotor-card Connector seen from outside to the female connector on the rotor-card.

Appendix3: Connection of rotor-card to ERC-M Mini-DIN rotor-card Signal D-SUB ERC-M

axis 1 D-SUB ERC-M axis 2

1 CW/UP 9 15

2 CCW/DOWN 2 7

3 AUX 11 13

4 Feedback-voltage 1 8

5 GND 10 14

6 DC-supply 12 12



Appendix4: Pin-out of the HID-connector on ERC-M 2 4 6 8 10 12 14 16

1 3 5 7 9 11 13 15

Pin Pin 1 GND 9 LCD E

2 VCC 10 LCD RS

3 Keyboard Common 11 LED AUX2

4 +5V 12 LED AUX1

5 LCD D7, Keyboard UP 13 LED DWN

6 LCD D6, Keyboard DWN 14 LED UP

7 LCD D5, Keyboard CW 15 LED CCW

8 LCD D4, Keyboard CCW 16 LED CW

Appendix5: Schematics Rotor-Card

5 3

1 2

4 6



Appendix6: Schematics ERC-M



Appendix7: Schematics HID

Documents

EASY-ROTOR-CONTROL M V2.2 Instructions