Integral Circuits CC 50 A User manual

Critter Control
Model CC 50 A
User Manual

Notice:
This Manual is no longer up to
date. All mentioned functions
are still the same in the new
hardware version, however
there have been additions and
some bug xed been made
that are not reected yet.
There will be an update of this
manual after the next hardware
turnaround.

Table of Contents
1. Introduction 5
What’s in the box? 5
1a. THE CC50A HANDSET 6
2. Handset - Before rst use 7
Inserting the rechargeable batteries into the handset. 7
Charging the handset batteries 7
Charger LED indicator codes: 8
Turning the handset on. 8
Turning the handset o󰀨. 8
3. System startup procedure 9
Startup: 9
4. System and Error Messages 10
User Induced E-STOP: 10
5. Control of your locomotive 11
Setting speed: 11
Changing direction: 11
Applying brakes: (With brake controller) 12
Stopping/slow down:(Without brake controller) 12
Locking brakes: (With brake controller) 13
Unlocking brakes: (With brake controller) 13
Checking locomotive battery voltages 13
Turning on the lights 14
Sounding the horn 14
Turning the bell on and o󰀨 14
6. Setup Menu 15
Entering the Setup Menu: 15
Changing menu settings. 16
Description of functions: 17
7. The CC50A (hardware setup) 18
Connections of the CC50A 18
Installing the radio Tranceiver 19
Installing the system connector 20
Installing the accessory connector 21
Horn installation variants 22
Installing the brake connector 23
Brake controller installation diagram (BC100) 24
Brake controller installation diagram (BC50) 24
Combo controller installation diagram (BHC100) 25
Installing the speed sensor 26
9. Wiring Diagram 28
Integral Circuits Critter Control Model CC50A Manual
Document Version 1.0 ©2016 Integral Circuits,

4
Locomotive MAC Address and S/N
Handset MAC Address and S/N
The CC50A utilizes a matched pair of radios . the following two labels are the ad-
dresses and serial numbers of the locomotive unit and handset
If there is no label here , the same label/
information can be also found on the radio
tranceiver and the mounting side of the
Locomotive unit.
If there is no label here, the same informa-
tion can be found on the back of the
handset.
Contains FCC ID: MCQ-PROS2B
The enclosed device complies with Part 15 of the FCC Rules.
Operation is subject to the following conditions:
(i.) this device may not cause harmful interference and
(ii.) this device must accept any interference received,
including interference that may cause undesired operation.
WARNING
Radio Transmitting Device
This handset contains a low power “spread spectrum”
radio transmitter. While the e󰀨ective radiation of this
device is less than 200mW and though care has been
taken to design this handset such that the location of
the antenna minimizes human exposure to its 2.4GHz
energy, care should be taken to hold the handset per de-
sign to limit futher exposure and to improve operational
performance.

5
1. Introduction
What’s in the box?
CC50A Locomotive control unit
CC50A Remote control Handset
CC50A Radio Tranceiver
12V Charger for CC50A Handset
Make sure your box contains everything listed below. If any pieces are missing, contact
the seller.
If this system got delivered pre-built into a locomotive, make sure that these items are
listed by your seller and nothing is missing.
Package of connectors
(pre-made connectors with specied wirelengths can be purchased separately)

6



1a. THE CC50A HANDSET
1. Main Display
2. Power Button
3. Flashlight button
4. Lights button
5. Horn button
6. Bell button
7. Forward button
8. Reverse button
9. Charging indicator
10. Locomotive Battery
Indicator
11. Remote Battery
Indicator
12. Horn indicator
13. Bell indicator
14. Direction indicator
15. Throttle/PSU/Speed
16. Throttle indicator
17. Lamp indicator
18. Brake button
19. Control Knob
20. Charging port
1
23
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20

7
2. Handset - Before rst
The handset can also be operated
with 2 regular AA Alkaline batteries.
However, the internal charger will only
work with rechargeable batteries.
WARNING: Do not attempt to use
the charger with alkaline batteries
installed!
Inserting rechargeable batteries into the handset.
(NiMH with at least 2000mAH are recommended)
!
Charging the handset batteries (with Rechargeable batteries
inserted)
To charge the handset batteries, plug the charger
into the receptactle on the bottom of the handset.
The LED on the front face of the handset marked
“charging” will indicate the charging mode and
status. How the codes for charging are read is
described on page 8.
12V charger plug

8
Press and hold the power button for 2 seconds.
You will see the splash-screen before the hand-
set shows the main dashboard. The handset is
now ready to use



 
Turning the handset on.
FWD>
0.0
Charger LED indicator codes:
Code:
Pre charge state - 1 short ash per second
Rapid Charge - led is equally on/o󰀨 per sec
Post charge - led ashes short twice
No battery detected - 5 short pulses
Post charge constant voltage mode - 3
short ashes
During charging, if the battery is deeply discharged, the charger will indi-
cate it is in a “pre-charge” state in which the battery voltage is brought up to
approximately .8V per cell before commencing rapid charge.
If the batterys are at .8V per cell or above, the charger will enter rapid
charge mode in which the batteries are charged at 500mA for a maximum
time of 5 hours
Please note: The charger will not start rapid charging the bat-
teries if they are still more than 50% charged.
Turning the handset o󰀨.
To turn the handset o󰀨 you have to press and hold the power button for another 2 - 3
seconds until it shows “info shutdown”

9
3. System startup procedure
1. Turn on the handset by pressing the power button for 2 sec-
onds
2. Turn the Key switch on your locomotive to ON. Position.
3. The CC 50A will go through a startup sequence.
4. When all system checks are done and turn out OK, it will start
ashing the system LED indicator while the Master Relay led will
become lit solid
5. press the brake button on the handset until the system LED
lights up solid .
Startup Error Messages:
These error messages appear if any of the system checks at startup return a
negative result.
The controller will check for battery voltage and motor drive/motor health, before
it unlocks the system for use
Low locomotive battery error:
Symptom: Solution:
Battery voltage shows 0 Check the wire and fuse for battery monitor 2
Battery voltage is ~ 18.0V Locomotive batteries need recharged.
Motor test failed error:
Symptom: Solution:
Motor short detected! Check the wiring of the motors for shorts.
Check the motors directly for shorts.
Startup:



1. 2. 3.
4. 5.
initially o󰀨
ashing solid press Both LEDs solid

LOCO BATTERY LOW
Low Battery Voltage: 0.02V

MOTOR TEST FAILED
Motor short detected!

FWD>
0.0

FWD>
0.0
Locomotive battery shows up.

10
4. System and Error Messages
User E-STOP:
This message shows when the power button is pressed while the
system is in operation.
It indicates that the locomotive entered the emergency stop state.
This can be cancelled with a push of the brake button.
Dropped handset E-STOP:
This message shows whenever the handset is dropped and been in
freefall for
longer than the period specied in the setup menu. (“fall time” page 17.)
Handset battery low warning:
This message shows whenever the batteries of the handset fall below
a charge voltage of 1.9v . This message is only shown for a short mo-
ment before the handset turns itself o󰀨. (safety shutdown)
Immediate recharging of the Handset batteries is adviced.
Overcurrent Warning:
The system triggers this message whenever the internal current limit of
approximately 75A is overstepped. This is a safety feature to prevent
damages to the motor or motor drive due to mechanical blockage or
overburdening of the locomotive.
Please note that the locomotive wont stop when this occurs, but the
internal safety will turn o󰀨 the drive on a per PWM cycle basis, and
limiting the current.
To dismiss this message you need to rotate the knob of the hand-
set a notch backwards.
Overheat E-STOP:
The system triggers an Cycle STOP whenever the internal temperature
sensors measure a tamperature above the safe zone for the internal
components.
This message can not be dismissed until the locomotive and hand-
set have been power cycled
System cool down before further use is adviced!

E-STOP
User E-STOP triggered
push Brake to reset

E-STOP
TX dropped!
push Brake to reset

TX battery low
Shutting down handset

OVERCURRENT!
overcurrent in motordrive
rotate knob to continue

OVERHEAT!
Motor controller overheat!
turn o󰀨 system!
User Induced E-STOP:
If you press the power button at any given time
the locomotive will go into an User requested
E-Stop. To cancel this you need to push the
brake - button once.

E-STOP
User E-STOP triggered
push Brake to reset

11

5. Control of your locomotive
FWD>
10% FWD> 80%
Setting speed: Make sure the brakes or brake lock are not active.
1. Turn the knob clockwise to increase speed.
2. turn the knob counter clockwise to decrease speed.
1. 2.
Changing direction: 1. press ‘forward’ to change the direction to forward
travel
2. press ‘reverse’ to change the direction to backward
travel.
Depending on the setting of reverse limit in the
Setup menu (page 18). you can change the direction
into the opposite way of travel while the locomotive
is throttled up. It will slow down and then reverse
into the opposite direction



1.



2.

FWD>
25% <REV 25%

12
Applying brakes: (With brake controller)
1. Press and hold the brake button. Throttle will be au-
tomatically reduced to 0% and brake pressure applied
at the set value. (factory setting is 15psi)*
2. Rotate the knob clockwise to increase pressure.
3. Rotate the knob counter clockwise to decrease pres-
sure.
Stopping/slow down:(Without brake controller)
1. Press the Brake button. Throttle will be reduced to 0%.
The four quadrant motor drive of the CC50A will slow
down the locomotive to a stop on an even surface.**
if you are on an inclined track piece , the locomotive
might continue to slowly creep forward or backward
down the track. You can prevent this by giving a little
bit of throttle in the opposite direction of travel
* Please Note that this is reversed when you set the Brake Button mode to inverted in the
Setup Menu. Not pressing the button operates the brakes in inverted mode. While press-
ing it means you can change the speed.
** When the brake button is set to inverted, releasing the button will stop the locomotive,
while pressing it means you can change the speed.
Warning! Above mentioned
method is only useful for
short stops.
DON’T keep the locomotive
throttled up stationary on an
inclined track piece for too
long. It can cause heat dam-
age to your motors!!
press
+
hold
1.
2. 3.

FWD>
5 psi
press
1.
!
FWD>
15 psi

13
Locking brakes: (With brake controller)
1. Press and hold the Brake button.
2. Press knob.
3. Release both brake button and knob.
The red LED on the brake button will light up, indicating
that the brake-lock mode is now active
Unlocking brakes: (With brake controller)
1. Press and hold the Brake button.
2. Press knob.
3. Release both brake button and knob.
The red LED on the brake button turn o󰀨, indicating that
the brake-lock mode is now inactive.
Note: Without brake - controller, this function does only maintain a
throttle value of 0. The locomotive might still creep on an inclined
track piece.
press
+
hold
1. 2. 3.
brake LED lights up
press
+
hold
1. 2. 3.
brake LED turns o󰀨
press
press
Checking locomotive battery voltages
This function does not work
in Brake Lock mode
1. Press the knob while not in brake-lock mode. The dis-
play switches from showing the regular dash to a screen
showing the voltages of the locomotive batteries.
 
Bat1: 12.3V
Bat2: 12.1V
FWD>
25%
1.
!

14
Turning on the lights
Sounding the horn
Turning the bell on and o󰀨
1. Press the “lights” button to turn on the headlights.
They will be bright in the direction of travel and dimmed
in the opposite direction. Meaning, at forward travel the
headlight will be bright, the rear one dim.
2. Once the lights are on, you may dim them by pressing
the button again. It will toggle back and forth between
bright and dim setting.
3. To turn the lights o󰀨, press and hold the button until the
lightbulb symbol on the LCD disappears and the lights
turn o󰀨.
1. Press the “bell” button. This will turn the bell pulse
signal on and will repeat until you turn the bell o󰀨 again.
2. Press the button again to turn the bell signal o󰀨.









1. Press the “horn” button, the horn should blow and
keep blowing as long as you keep the button pressed. It
will turn o󰀨 as soon as you release the button




15
Entering the Setup Menu:
1. Press and hold the brake button.
2. With the brake button held, press the knob.
3. release both brake button and knob. The red LED on
the brake button will be lit (brake lock mode see page 9.)
4. Now press and hold the knob for a few seconds.
5. The handset enters the setup menu.
6. Setup Menu
press
+
hold
1. 2. 3.
brake LED lights up
press &
hold 3-4sec.
release
press
 
Max Throttle
100%
FWD>
15psi
4.
3.

16
Please note that the CC50A controller needs to be turned on for
the values to be stored internally. The System won’t take the
changes if the CC50A is turned o. Only settings that can be
changed oine are:
deadman time, fall time, reverse limit, deadman mode,
brakebutton mode and backlight mode.
!
Changing menu settings.
1. Use the knob to choose which menu setting you want to
change.
2. Press the knob to change the currently selected setting.
3. A rectangle will appear around the value.
4. Now use the knob to change the value.
5. Press the knob again and the menu will ask you if you want
to save: Yes = save change. No = dismiss change.
6. Press the brake button (menu cancel) at any time and the
handset will return to the dash in brake-lock mode. You can
re-enter the menu by just holding down the knob again for a
moment.
List of available settings:
Name Value Range
Max Throttle 10-100%
Default PSI 1-50psi
Maximum PSI 10-50psi
Acceleration 15-25% per sec
Deceleration 15-25% per sec
Wheel Diameter 3.0-8.0 inch
Deadman Time 1-30 seconds
Fall Time 1 - 100ms
RHL Dimming level 1 to 4
Reverse Limit 5 - 50% of throttle
Deadman Mode o󰀨 / on
Brake button Mode normal / inverted
Backlight Mode o󰀨 / fade / dim / bright

Max Throttle
100%

Max Throttle
85%

Max Throttle
100%
press to exit
Save? YES NO
1.
2.
3.
4.
5.
6.
press
press

17
Sets the maximum throttle. This gives the operator the ability to limit the
maximum speed of the locomotive. I.E to have an inexperienced operator
use the locomotive.
Sets the default pressure of the brake system to the value specied.
This is the pressure setting that the system is set to at startup and at
E-STOPs.
Sets the maximum pressure of the brakes
Sets the rate at which the locomotive will accelerate in percent per
second.
Sets the rate at which the locomotive will decelerate in percent per
second.
Sets the diameter of the wheel that the speed sensor is reading from. This
setting is crucial for correct speed measurement.
Sets the duration for timeout of the deadman system. The handset will
stop the locomotive after this set of time if no input to any of the controls
of the handset has been received.
Sets the timeframe in milliseconds the handset has to be in free-fall after
being dropped before the drop detection triggers. (fall detection sensitiv-
ity)
shorter time = more sensitive longer time = less sensitive.
Sets the maximum brightness of the Rear Light.
Can be set to one of four levels with level 1 being the dimmest and level
4 being the brightest.
Sets the maximum speed where you can just reverse the locomotive with
the directional buttons. (i.e traveling forward and then just reversing) The
locomotive will slow down at the rate set in deceleration. then accelerate
in the opposite direction at the rate set in acceleration.
Turns the deadman mode on or o󰀨. When this is turned on, you have to
keep rotating the knob or press any of the buttons to keep the deadman
from timing out. The Timeout timeframe can be set with the “Deadman
Time”. setting
Sets how the Brake button is handled by the system.
normally the system sets speed via the knob until you press the brake
button, then you set brake pressure and the locomotive stops.
in inverted mode, this is reversed. The system sets brake pressure, and
the locomotive is stopped until you press the button, then it releases the
brakes and you can set speed with the knob.
Sets the background light of the handset to one of the four following set-
tings:
o󰀨 = always o󰀨. (most battery saving)
fade = backlight turns on when any input is received then fades out
(balanced)
dim = always on at a dim setting (moderate battery saving)
bright = always on at full brightness (least battery saving)
Max Throttle-
Default PSI-
Max PSI-
Acceleration-
Deceleration-
Wheel diameter-
Deadman Time-
Fall Time-
RHL Dimming-
Reverse Limit-
Deadman Mode-
Brake Button
Mode-
Backlight Mode-
Description of functions:

18
7. The CC50A (hardware set-
up)
1
2
3
45
6
7
8
9
10
11
12
13
14
1. System Connector
2. Lights / Horn / Bell Connector
3. Radio Connector
4. Front Power connector
5. Rear Power connector
6. Train Brakes connector
7. Speed sensor input
8. Fuse sensor input
9. Main RY and Status LED
10. Positive Motor Lug
11. Negative Motor Lug
12. Positive Battery Lug
13. Negative Battery Lug(GND)
14. Heatsink
KSI, VBat1, Vbat2
Front light, Rear light, Horn, Bell
5V, GND, RX,TX, RTS,CTS,Radio-con
12V,GND
12V,GND
Apply,Release,PSI-input,12V,GND
Input, 5V, GND
Input, 5V, GND
-
-
-
-
-
-
connector connections
Connections of the CC50A

19
Installing the radio Tranceiver
When you install the tranceiver you need to make
sure that the antenna is clear of any obstructions
1. 8pin radio tranceiver plug
2. Radio antenna
3. Activity / Connection LED (on backside)
!
Plug the radio tranceiver into the 8 pin receptacle on the frontpanel of the CC50A controller
1
2
3

20
Installing the system connector
Plug the 4 pin system connector into the upper left 4 pin receptacle.
The pinout for this connector is as described here:
KSI and Battery 2 Are absolutely mandatory for
installation. The system wont start up with either
missing.
!
Key switch input (KSI)
no connection
Battery 2 (24v system monitor)
Battery 1 ( 12v monitor )
This connection should be fused
with a 3A Fuse (minimum)
(mandatory connection)
This connection should be fused
with a 0.5A Fuse (minimum)
(mandatory connection)
This connection should be fused
with a 0.5A Fuse (minimum)