erc EASY-ROTOR-CONTROL M, ERC-M Instructions Manual

EASY-ROTOR-CONTROL M V2.2 Instructions

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

___________________________________________________________________________

This document is for the user only. Any publishing (printed or in electronic form) is not allowed.

EASY-ROTOR-CONTROL M V2.2 Instructions

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.

___________________________________________________________________________

This document is for the user only. Any publishing (printed or in electronic form) is not allowed.

EASY-ROTOR-CONTROL M V2.2 Instructions

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

C3,C4,C6,C9,C10,

9 Capacitor ceramic 100n 50V 20% 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% 2 Resistor 220K 5% R5,R9 alt. 220K 1% 4 Coil 10u 10% SMCC L1,L2,L3,L4

8 Diode BAT48 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

C11,C12,C13,C14

D2,D3,D4,D5,D6, D8,D9,D10

___________________________________________________________________________

This document is for the user only. Any publishing (printed or in electronic form) is not allowed.

EASY-ROTOR-CONTROL M V2.2 Instructions

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

___________________________________________________________________________

This document is for the user only. Any publishing (printed or in electronic form) is not allowed.

EASY-ROTOR-CONTROL M V2.2 Instructions

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

___________________________________________________________________________

This document is for the user only. Any publishing (printed or in electronic form) is not allowed.

EASY-ROTOR-CONTROL M V2.2 Instructions

USB-Module

___________________________________________________________________________

This document is for the user only. Any publishing (printed or in electronic form) is not allowed.

EASY-ROTOR-CONTROL M V2.2 Instructions

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

___________________________________________________________________________

This document is for the user only. Any publishing (printed or in electronic form) is not allowed.

EASY-ROTOR-CONTROL M V2.2 Instructions

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 DCcable 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

___________________________________________________________________________

This document is for the user only. Any publishing (printed or in electronic form) is not allowed.

EASY-ROTOR-CONTROL M V2.2 Instructions

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.

___________________________________________________________________________

This document is for the user only. Any publishing (printed or in electronic form) is not allowed.

EASY-ROTOR-CONTROL M V2.2 Instructions

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 QTY Type Value Reference Comments

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

C3,C4,C6,C9,C10,C11,

10 Capacitor ceramic 100n 50V 20%

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% 2 Resistor 39K 5% R4,R8 alt. 39K 1% 2 Resistor 220K 5% R5,R9 alt. 220K 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 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 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

C12,C13,C14,C22

___________________________________________________________________________

This document is for the user only. Any publishing (printed or in electronic form) is not allowed.

EASY-ROTOR-CONTROL M V2.2 Instructions

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.

___________________________________________________________________________

This document is for the user only. Any publishing (printed or in electronic form) is not allowed.

EASY-ROTOR-CONTROL M V2.2 Instructions

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 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.

___________________________________________________________________________

This document is for the user only. Any publishing (printed or in electronic form) is not allowed.

EASY-ROTOR-CONTROL M V2.2 Instructions

___________________________________________________________________________

This document is for the user only. Any publishing (printed or in electronic form) is not allowed.

EASY-ROTOR-CONTROL M V2.2 Instructions

___________________________________________________________________________

This document is for the user only. Any publishing (printed or in electronic form) is not allowed.

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