EASY-ROTOR-CONTROL 3D V1.2_1
Instructions
Instructions
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-Instructions ................................................................................................................. 2
1. Bill of Material (BOM) ...................................................................................................... 2
2. Assembly of RS232 cable .................................................................................................. 4
3. Assembly of the Controller PCB........................................................................................ 6
4. Connection of the DC-supply and check of the voltage-regulator................................... 10
5. Assembly of the LED-PCB .............................................................................................. 11
6. Assembly of the flat-ribbon-cable.................................................................................... 12
7. Installation of the Service Tool ........................................................................................ 13
8. Connect the ERC-3D to the PC........................................................................................ 13
9. Configuration of the Service Tool.................................................................................... 13
9.1 Configuration of the COM-Port ................................................................................. 14
9.2 Read the ERC-3D-configuration-parameters ............................................................. 14
9.3 Language .................................................................................................................... 14
9.4 Other functions of the Service Tool ........................................................................... 15
10. Installation of the ERC-3D............................................................................................. 15
10.1 Theory of operation .................................................................................................. 15
11. Calibration ...................................................................................................................... 15
12. First check of calibration with Rotor-Control 3D .......................................................... 15
13. First check of calibration with PstRotator-Lite .............................................................. 16
14. Connect the ERC-3D to other programs ........................................................................ 17
15. Optional LCD-display .................................................................................................... 18
15.1. Assembly of the flat-ribbon-cable........................................................................... 18
15.1. Finalize the LCD-Display ....................................................................................... 18
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Instructions
EASY-ROTOR-CONTROL 3D V1.2_1
Safety-Instructions
•
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•
•
•
•
•
•
•
•
•
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
10 Capacitor ceramic
2-layer 107x65mm V1.0
100n 50V 20%
2.5
C3,C5,C12-C19
1 Crystal
9.8304 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%
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
2.5
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Instructions
EASY-ROTOR-CONTROL 3D V1.2_1
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
4 Diode
BAT48
2.5
2 Diode
P6KE33CA
3.81
D5,D12
1 Diode
1N4004
2.5
D1
3 Coil
10u 10% SMCC
2.5
L1,L2,L3
2 Pinheader
2x5 pol.
2.54
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
1 Capacitor Al
100u 16V 20%
1 Relay
G6D-1A-ASI12VDC
4 Relais
FTR F1CA012V
K1,K2,K4,K5
1 Voltage-Regulator
7805 TO220
IC3
R15
D6,D7,D10,D11
X1
2.5
alt.: BAT42
alt.: 1N4005-4007
DC
C4
K3
alt.: LMR2-12D
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
3 Cable-Ties
150mm
for DC
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.
2.54
JP3
2 Distance-Bolt
M3x8x6mm
2 Spring-Wascher
3.2mm
2 Nuts
M3
2 Screw
M3x6mm
0,2 Flat ribbon cable
2 Connector
1m 10 pol.
1.27
2x5 pol.
2.54
for flat ribbon cable
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EASY-ROTOR-CONTROL 3D V1.2_1
Instructions
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
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EASY-ROTOR-CONTROL 3D V1.2_1
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.
Instructions
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.
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EASY-ROTOR-CONTROL 3D V1.2_1
Instructions
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
=
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EASY-ROTOR-CONTROL 3D V1.2_1
Instructions
__________________________________________________________________________________________
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EASY-ROTOR-CONTROL 3D V1.2_1
Instructions
__________________________________________________________________________________________
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EASY-ROTOR-CONTROL 3D V1.2_1
Instructions
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:
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EASY-ROTOR-CONTROL 3D V1.2_1
Instructions
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
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Instructions
EASY-ROTOR-CONTROL 3D V1.2_1
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.
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EASY-ROTOR-CONTROL 3D V1.2_1
Instructions
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:
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EASY-ROTOR-CONTROL 3D V1.2_1
Instructions
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.
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Instructions
EASY-ROTOR-CONTROL 3D V1.2_1
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.
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EASY-ROTOR-CONTROL 3D V1.2_1
Instructions
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.
10.1 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 0..360° and Elevation 0..180°) 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.
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EASY-ROTOR-CONTROL 3D V1.2_1
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 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.
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EASY-ROTOR-CONTROL 3D V1.2_1
Instructions
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
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Instructions
EASY-ROTOR-CONTROL 3D V1.2_1
15. Optional LCD-display
LCD Assembly
1 LCD-Display
0,2 Flat ribbon cable
1 Connector
2 Resistor
4 Distance-Bolt
4 Spring-Wascher
4 Nuts
4 Screw
16x2
1m 10 pol.
2x5 pol.
27R 5%
M3x8x6mm
3.2mm
M3
M3x6mm
1.27
2.54
for flat ribbon cable
15.1. 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.
15.1. 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
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EASY-ROTOR-CONTROL 3D V1.2_1
Instructions
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:
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Instructions
EASY-ROTOR-CONTROL 3D V1.2_1
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.
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