erc EASY-ROTOR-CONTROL M User manual

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 : [e-mail]
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

EASY-ROTOR-CONTROL M V2.2 Instructions
___________________________________________________________________________
© Ing.-Büro E. Alba de Schmidt web : www.schmidt-alba.de
Tannenstr. 16 Page 2 of 44 email : [e-mail]
86836 Untermeitingen / Germany
This document is for the user only. Any publishing (printed or in electronic form) is not allowed.
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.

EASY-ROTOR-CONTROL M V2.2 Instructions
___________________________________________________________________________
© Ing.-Büro E. Alba de Schmidt web : www.schmidt-alba.de
Tannenstr. 16 Page 3 of 44 email : [e-mail]
86836 Untermeitingen / Germany
This document is for the user only. Any publishing (printed or in electronic form) is not allowed.
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%
2 Resistor 220K 5% R5,R9 alt. 220K 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

EASY-ROTOR-CONTROL M V2.2 Instructions
___________________________________________________________________________
© Ing.-Büro E. Alba de Schmidt web : www.schmidt-alba.de
Tannenstr. 16 Page 4 of 44 email : [e-mail]
86836 Untermeitingen / Germany
This document is for the user only. Any publishing (printed or in electronic form) is not allowed.
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
=

EASY-ROTOR-CONTROL M V2.2 Instructions
___________________________________________________________________________
© Ing.-Büro E. Alba de Schmidt web : www.schmidt-alba.de
Tannenstr. 16 Page 5 of 44 email : [e-mail]
86836 Untermeitingen / Germany
This document is for the user only. Any publishing (printed or in electronic form) is not allowed.
Not to be assembled components are marked grey in the assembly drawing.

EASY-ROTOR-CONTROL M V2.2 Instructions
___________________________________________________________________________
© Ing.-Büro E. Alba de Schmidt web : www.schmidt-alba.de
Tannenstr. 16 Page 6 of 44 email : [e-mail]
86836 Untermeitingen / Germany
This document is for the user only. Any publishing (printed or in electronic form) is not allowed.
USB-Module

EASY-ROTOR-CONTROL M V2.2 Instructions
___________________________________________________________________________
© Ing.-Büro E. Alba de Schmidt web : www.schmidt-alba.de
Tannenstr. 16 Page 7 of 44 email : [e-mail]
86836 Untermeitingen / Germany
This document is for the user only. Any publishing (printed or in electronic form) is not allowed.
Check carefully the assembly. So, this is how it should look like.

EASY-ROTOR-CONTROL M V2.2 Instructions
___________________________________________________________________________
© Ing.-Büro E. Alba de Schmidt web : www.schmidt-alba.de
Tannenstr. 16 Page 8 of 44 email : [e-mail]
86836 Untermeitingen / Germany
This document is for the user only. Any publishing (printed or in electronic form) is not allowed.
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

EASY-ROTOR-CONTROL M V2.2 Instructions
___________________________________________________________________________
© Ing.-Büro E. Alba de Schmidt web : www.schmidt-alba.de
Tannenstr. 16 Page 9 of 44 email : [e-mail]
86836 Untermeitingen / Germany
This document is for the user only. Any publishing (printed or in electronic form) is not allowed.
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.

EASY-ROTOR-CONTROL M V2.2 Instructions
___________________________________________________________________________
© Ing.-Büro E. Alba de Schmidt web : www.schmidt-alba.de
Tannenstr. 16 Page 10 of 44 email : [e-mail]
86836 Untermeitingen / Germany
This document is for the user only. Any publishing (printed or in electronic form) is not allowed.
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
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%
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

EASY-ROTOR-CONTROL M V2.2 Instructions
___________________________________________________________________________
© Ing.-Büro E. Alba de Schmidt web : www.schmidt-alba.de
Tannenstr. 16 Page 11 of 44 email : [e-mail]
86836 Untermeitingen / Germany
This document is for the user only. Any publishing (printed or in electronic form) is not allowed.
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.

EASY-ROTOR-CONTROL M V2.2 Instructions
___________________________________________________________________________
© Ing.-Büro E. Alba de Schmidt web : www.schmidt-alba.de
Tannenstr. 16 Page 12 of 44 email : [e-mail]
86836 Untermeitingen / Germany
This document is for the user only. Any publishing (printed or in electronic form) is not allowed.
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.

EASY-ROTOR-CONTROL M V2.2 Instructions
___________________________________________________________________________
© Ing.-Büro E. Alba de Schmidt web : www.schmidt-alba.de
Tannenstr. 16 Page 13 of 44 email : [e-mail]
86836 Untermeitingen / Germany
This document is for the user only. Any publishing (printed or in electronic form) is not allowed.

EASY-ROTOR-CONTROL M V2.2 Instructions
___________________________________________________________________________
© Ing.-Büro E. Alba de Schmidt web : www.schmidt-alba.de
Tannenstr. 16 Page 14 of 44 email : [e-mail]
86836 Untermeitingen / Germany
This document is for the user only. Any publishing (printed or in electronic form) is not allowed.

EASY-ROTOR-CONTROL M V2.2 Instructions
___________________________________________________________________________
© Ing.-Büro E. Alba de Schmidt web : www.schmidt-alba.de
Tannenstr. 16 Page 15 of 44 email : [e-mail]
86836 Untermeitingen / Germany
This document is for the user only. Any publishing (printed or in electronic form) is not allowed.
Check carefully the assembly. So, this is how it should look like.

EASY-ROTOR-CONTROL M V2.2 Instructions
___________________________________________________________________________
© Ing.-Büro E. Alba de Schmidt web : www.schmidt-alba.de
Tannenstr. 16 Page 16 of 44 email : [e-mail]
86836 Untermeitingen / Germany
This document is for the user only. Any publishing (printed or in electronic form) is not allowed.
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

EASY-ROTOR-CONTROL M V2.2 Instructions
___________________________________________________________________________
© Ing.-Büro E. Alba de Schmidt web : www.schmidt-alba.de
Tannenstr. 16 Page 17 of 44 email : [e-mail]
86836 Untermeitingen / Germany
This document is for the user only. Any publishing (printed or in electronic form) is not allowed.
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.

EASY-ROTOR-CONTROL M V2.2 Instructions
___________________________________________________________________________
© Ing.-Büro E. Alba de Schmidt web : www.schmidt-alba.de
Tannenstr. 16 Page 18 of 44 email : [e-mail]
86836 Untermeitingen / Germany
This document is for the user only. Any publishing (printed or in electronic form) is not allowed.
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
QTY Type Value Reference Comments
1 Diode 1N4004 D12 alt. 1N4007
2 Capacitor ceramic 100n 50V 20% C15,C16
1 Capacitor Tantal 1u 35V 20% C23
2 Resistor 10K 5% R1,R12 alt. 10K 1%
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 :
=

EASY-ROTOR-CONTROL M V2.2 Instructions
___________________________________________________________________________
© Ing.-Büro E. Alba de Schmidt web : www.schmidt-alba.de
Tannenstr. 16 Page 19 of 44 email : [e-mail]
86836 Untermeitingen / Germany
This document is for the user only. Any publishing (printed or in electronic form) is not allowed.

EASY-ROTOR-CONTROL M V2.2 Instructions
___________________________________________________________________________
© Ing.-Büro E. Alba de Schmidt web : www.schmidt-alba.de
Tannenstr. 16 Page 20 of 44 email : [e-mail]
86836 Untermeitingen / Germany
This document is for the user only. Any publishing (printed or in electronic form) is not allowed.
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