Renard-Plus TR24 User manual
TR24 Controller
Aug 2016
Board Version 1.00 (v.1_05032013)
Document Rev 1.13
Renard-Plus, Salem, Oregon 97302
© 2011-2015 Renard Plus. All rights reserved.
Published 2016
Printed in United States
Renard-Plus (“Developer”) has made every effort to ensure the accuracy of this document. Developer makes no warranties with respect to
this documentation and disclaims any implied warranties of merchantability and fitness for a particular purpose. The information in this
document is subject to change without notice. Developer assumes no responsibility for any errors that may appear in this document.
The information contained herein is the exclusive and confidential property of Renard Plus, except as otherwise indicated.
We wish to also thank the Do It Yourself Community for the inspiration it has given us in the development of this product.
Trademarks: the Renard Plus logo are trademarks of Renard Plus. All other trademarks acknowledged.
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Table of Contents
TABLE OF CONTENTS...................................................................................................................................................2
1. INTRODUCTION TO RENARD .............................................................................................................................3
2. OVERVIEW OF RENARD PLUS TR24 .................................................................................................................4
3. ASSEMBLY INSTRUCTIONS................................................................................................................................5
3.1 RENARD PLUS TR24 BOM /PARTS LIST ..............................................................................................................5
3.1.1 Transformer Options ...............................................................................................................................6
3.1.2 TR24 Heatsink.........................................................................................................................................7
3.1.3 TR24 Enclosure.......................................................................................................................................7
3.2 PARTS ASSEMBLY................................................................................................................................................8
3.2.1 First Things First......................................................................................................................................8
3.3 TR24 ASSEMBLY GUIDE ......................................................................................................................................9
3.3.1 Select Voltage Setting.............................................................................................................................9
3.3.2 Install Resistors.....................................................................................................................................10
3.3.3 Install By-pass Caps and Diodes ..........................................................................................................12
3.3.4 Install IC Sockets...................................................................................................................................13
3.3.5 Install IC Headers..................................................................................................................................14
3.3.6 Install Misc. Parts ..................................................................................................................................15
3.3.7 Initial Testing .........................................................................................................................................19
3.3.8 Install IC’s ..............................................................................................................................................20
3.3.9 Picture of Finished Board......................................................................................................................21
4. FINISHING STEPS...............................................................................................................................................22
4.1 PROGRAMMING THE PIC....................................................................................................................................22
4.2 JUMPER SETTINGS /HEADERS............................................................................................................................22
4.2.1 JP1 RS485 Terminator..........................................................................................................................22
4.2.2 JP2 RenW / XBee Header.....................................................................................................................22
4.2.3 JP3 PIC Bypass / DMX .........................................................................................................................23
4.2.4 Programming (ICSP Header)................................................................................................................23
4.2.5 Ground and +5 Test Points...................................................................................................................23
4.3 CONNECTING THE RENARD TO YOUR PC.............................................................................................................24
4.3.1 RJ45 Wiring...........................................................................................................................................24
4.3.1 DMX wiring............................................................................................................................................24
4.3.2 Computer Setup ....................................................................................................................................25
4.4 FINAL TESTING ..................................................................................................................................................25
4.4.1 Diagnostic LED Status Lights................................................................................................................25
4.4.2 Test Procedure......................................................................................................................................25
5. PARTS PLACEMENT DIAGRAM........................................................................................................................26
6. NOTES .................................................................................................................................................................27
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Renard Plus TR24 Controller
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1. Introduction to Renard
Renard is the name of a “do-it-yourself” (DIY), computer-controlled, PIC-based dimmer light
control concept. It also refers to a family of dimming controllers that have been designed and built
based on this concept.
The Renard design concept was originally described by Phil Short in the Simple PIC-Based 8-Port
Dimmer 'How-To' on the http://computerchristmas.com website. Since then there have been many
enhancements and new designs based on this hardware. There have been many contributors to
advancing Renard technology including M. Macmillan, D. Davis, P. Rogers, T. Straub, D. Haberle,
A. Williams and others
Renard controllers typically rely on a separate computer running a light sequencing program to
send it real-time sequences of controller commands to sequence the lights. The computer
communicates with the Renard via RS232, RS485, or wireless (depending on the design) and the
Renard controls the lights either through built-in power control (power is output directly to the
lights), or via separate “SSRs” (solid state relays supply the power when commanded by the
controller).
Renard
Renard SSR
SSR
SSR
SSR
SSR
Example Renard configurations
Output of the Renard can be either control signals (to an SSR), direct AC line voltage (110,
100/220, or 220), or DC voltage depending on the design.
Renard is a DIY hobbyist effort and there is a vast amount of products and related peripherals to
select from including the Renard Plus Strip Controller. To obtain a specific design, there might be
“buy a parts kit and/or blank PCB” offering at a site (such as from www.renard-plus.com), “etch it
yourself” files for true DIY, or coop/group buys for kits and PCBs also in forums (like
DIYChristmas.org).
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2. Overview of Renard Plus TR24
This guide covers the Renard Plus TR24. This board is designed to take “Renard” serial
communications via RS485 from a control computer, and output line level AC to directly power
lights/and light strings. The board outputs 24 individually controllable/dimmable channels. The
Feature
Detail
Name
Renard Plus TR24
Target use
AC line level light control
Channel Count
24
Power input
110v or 220v line level AC
Power output
Yes –direct line level AC out –2 banks @
15A max each, 4A max per channel up to
bank max
Dimmable?
YES –PWM
Status Indicators?
YES
Channel Indicators?
NO
Control Input –Renard
YES –RS485, RS232 or optional wireless
Control Input –DMX
Planned
Daisy-chain output
YES –Renard RS485 pinout
Wireless
Option –w/add-on Xbee Snap-In board
On board programming
Yes through ICSP connector
Enclosure
CG1500
Heatsink?
Options –see template
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3. Assembly Instructions
This section covers the construction of the Renard Plus TR24 controller board. It approaches
these tasks as a learning exercise for new builders, so that they can develop proficiency and self-
confidence. The project itself is quite simple and if you follow the steps carefully, you should have
a working controller when you are done. Additional information and guides on techniques and
tools can be found in the “Tools and Parts ID Guide” at:
www.renard-plus.com/files/Tools_and_Parts_ID_Guide.pdf
3.1 Renard Plus TR24 BOM / Parts List
The following is the Bill Of Material for building the Renard Plus TR24. The link to the Mouser
project is: http://www.mouser.com/ProjectManager/ProjectDetail.aspx?AccessID=587c062e79
Picture
Designators
Description
Qty
Mouser P/N
For 110v operation
R1-12,
R48-59 -and-
180 ohm resistor 1/8 watt
operation -and-
24
299-180-RC
-and-
R30, R35
330 ohm resistor 1/8 watt
2
299-330-RC
-OR for 220v-
R1-12, R30, R35
R48-59
330 ohm resistor 1/8 watt
26
299-330-RC
R13-R24, R36-R47
680 ohm resistor 1/8 watt
24
299-680-RC
R25, R26, R28, R31,
R32
1k ohm resistor 1/8 watt
5
299-1k-RC
R27
120 ohm resistor 1/8 watt
1
299-120-RC
R29, R33
27k ohm resistor 1/8 watt
2
299-27k-RC
R34
10k ohm resistor 1/8 watt
1
299-10k-RC
D1
1N5229 (4.3v) zener diode
1
78-1N5229B
D2
1N5239 (9.1v) zener diode
1
78-1N5239B
C1
1000uf 25V Electrolytic Cap
1
647-UVZ1E102MPD
C3
220uf 25V Electrolytic Cap
1
647-UVZ1E221MPD
C2, C4, C5, C6, C7
.1uf cap
5
81-RDER71H104K0K103B
CH1 –CH24, AC IN,
and AC IN
Terminal Blocks 5.08MM PCB
24
571-2828372
ACIN_1, and ACIN_2
Terminal Blocks 5.08MM PCB
2
571-7969492
J1-J2
Modular Jacks 8 PCB TOP
ENTRY
2
571-5556416-1
IC3
40 pin IC Socket
1
Opt.
517-1-390262-5 or
649-DILB40P223TLF
IC4
8 pin IC socket (optional)
1
Opt.
571-1-2199298-2 or
517-4808-3004-CP
M1-M24, IC1
6 pin IC sockets (optional)
25
Opt.
571-1-2199298-1
ICSP, JP1, JP2, JP3
16 pin header cut to fit
1
571-16404526
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Renard Plus TR24 Controller
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Shunts for “RenW Snap In”,
“Bypass”, and TERM
3
649-63429-202LF
T1-T24
Triac 6AMP snubberless
24
511-BTA06-600CW
IC1
H11AA1
1
782-H11AA1
IC2
LM7805CT voltage regulator
1
512-LM7805CT
IC3
PIC Microcontrollers (MCU)
PIC18F4520 or 4620 and 4525
1
579-PIC18F4520-I/P
IC4
65LBC179
1
595-SN65LBC179P
IC5 (BR1)
4 pin Bridge rectifier 1amp dip
1
625-DF02MA-E3
M1-M24
Triac Output Optocouplers
MOC3023
24
859-MOC3023
STATUS
Yellow 5 MM LED
1
78-TLHY5405
PWR
Red 5 MM LED
1
78-TLHR5401
RX TX
Green 5 MM LED
1
78-TLHG5401
F1, F2
Fuse Clips and Holders PC
FUSE CLIP 5 MM
4
534-3517
F1, F2
5mm x 20mm 125VAC 12.5A
2
693-0034.3128.TR
F1. F2
Fuse Cover (optional)
2
Opt.
534-3527C
TR-1
Transformer
Pri.=115/230volts
Sec.=8volts 800ma.
1
838-3FD-416
(See other options in the
next section)
3.1.1 Transformer Options
The Parts list above only calls out one of the many transformers that can be used on this
controller board. The following are other transformers that can be used:
Primary Winding Secondary Winding Mouser Part Number
Mouser P/N
Primary
Volts (AC)
Sec. Volts
(AC)
Current
(ma)
Dual
Voltage
838-3FD-412
115 / 230
6.3
1000
838-3FD-416
115 / 230
8.0
800
838-3FD-420
115 / 230
10.0
600
838-3FD-424
115 / 230
12.0
500
838-3FD-312
115 / 230
6.3
400
838-3FD-316
115 / 230
8.0
300
Single
Voltage
838-3FS-412
115
6.3
1000
838-3FS-416
115
8.0
800
838-3FS-420
115
10.0
600
838-3FS-424
115
12.0
500
838-3FS-312
115
6.3
400
838-3FS-316
115
8.3
300
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Renard Plus TR24 Controller
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3.2 Parts Assembly
The Renard Plus TR24 is a fairly simple device to assemble and test. It is easiest if you follow
these instructions, checking off steps as they are performed. This will lead you through the
assembly installing components from shortest/smallest to tallest.
3.2.1 First Things First
1. Begin by inspecting the PCBs to look for any defects such as cracks or breaks. The holes
on the board should be open on both sides. Then inspect and sort out the various parts for
the board.
2. Next inspect and sort out the various parts for the board. Make sure you understand which
parts are which, and things like resistor codes and component orientation. A separate
document on these concepts is available at:
www.renard-plus.com/files/Tools_and_Parts_ID_Guide.pdf
and on other resource sites like Wikipedia.
3. Follow the assembly guide as follows in the next section.
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3.3 TR24 Assembly Guide
3.3.1 Select Voltage Setting
Step
Instructions
TR24
1a
115
VAC
Option
-OR-
If the controller will be used with 115 volt AC
main power, use 2 leftover leads that were
clipped and form them to individually jumper the
two sets of “115”positions near the transformer.
Note: DO NOT JUMPER ALL
of the voltage selection pads.
Use one set or the other!
Note: R1-R12 and R48-R59 will be 180 ohm
for this option in step 2a.
1b
220
VAC
Option
If the controller will be used with 220 VAC main
power, only jumper the “230”position.
Note: DO NOT JUMPER ALL
of voltage selection pads.
Note: R1-R12 and R48-R59
will be 330 ohm for this option in step 2b.
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3.3.2 Install Resistors
Resistors do not have a specific orientation and can be installed either direction. The VALUE is
important and that is indicated by the colored strips. See the Tools and Parts ID document on
www.renard-plus.com for details.
Step
Instructions
TR24
2a
-OR-
For 110v operation, Install 24 of 180 ohm
resistors (brown-gray-brown) at locations R1-
R12, and R48-R59. Solder and clip leads.
2b
For 220v operation Install 24 of 330 ohm
resistors (orange-orange-brown) at locations R1-
R12, and R48-R59. Solder and clip leads.
3
Install 24 of 680 ohm resistors (blue-gray-brown)
at locations R13-R24 and R36-R47. Solder and
clip leads.
4
Install 5 of 1K ohm resistors (brown-black-red) at
locations R25, R26, R28, R31, and R32. Solder
and clip leads.
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Step
Instructions
TR24
5
Install the 120 ohm resistor (brown-red-brown)
at locations R27. Solder and clip leads.
6
Install 2 of 27k ohm resistors (red-violet-orange)
at locations R29, R33. Solder and clip leads.
7
Install 2 of 330 ohm resistors (orange-orange-
brown) at locations R30, R35. Solder and clip
leads.
8
Install the 10k ohm resistor (brown-black-
orange) at locations R34. Solder and clip leads.
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3.3.3 Install By-pass Caps and Diodes
Step
Instructions
TR24
9
Install 5 of the .1uf (usually marked 104)
capacitors at locations C2, C4, C5, C6, C7.
Solder and clip leads.
Note: Bypass caps do NOT have a specific
orientation.
10
Install the small glass diode 1N5229 at location
D1.
Note: diodes have a specific
orientation. The diode has a band on
one end and should be installed matching the
silkscreen on the board (band should be to the
right toward the center of the board).
11
Install the small glass diode 1N5239 at locations
D2. Solder and clip leads.
Note: diodes have a specific orientation. The
diode has a band on one end and should be
installed matching the silkscreen on the board
(band should be to the right toward the center of
the board).
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Pin 1 of the IC socket is
on the end, closest to
the notch.
3.3.4 Install IC Sockets
Even though sockets are optional we strongly recommend that sockets be used on all of the IC’s.
This allows easier testing, debug and repair down the road. Sockets should be installed with the
Pin 1 of the socket aligned to the square solder pad on the PCB. The silkscreen also indicates a
notch on the socket outline that the notch on the socket should match. If you get a socket
backwards, it will work, but later you will need to be careful to install the IC properly per the board
indication of pin 1, not the socket. See diagram below.
Step
Instructions
TR24
12
Install the 40 pin IC socket at location IC3.
Solder.
13
Install the 8 pin IC socket at location IC4. Solder
14
Install 25 of the 6 pin IC sockets at locations M1-
M24, and IC1. Solder
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3.3.5 Install IC Headers
You may have purchased either a single 16 pin header or headers cut according to the board
specifications. If you followed the BOM, you will have a single 16 pin header that needs to be cut
into the appropriate lengths.
Step
Instructions
TR24
15
Install 2 pin header at location JP1 RS485 term.
Solder.
Install a shunt jumper on the two pins of the
header to enable Terminate of the RS485
communications on the last board in a daisy-
chained set of boards. Leave un-jumpered for
RS232.
16
Install 5 pin header at location JP2 / RenW Snap
In. Solder
Install a shunt jumper on the two left most pins
of the header as indicated on the silkscreen.
17
Install 3 pin header at location JP3 / PIC
Bypass. Solder
Install a shunt jumper on the two left most pins
of the header as indicated on the silkscreen.
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Step
Instructions
TR24
18
Install 6 pin header at location ICSP. Solder.
3.3.6 Install Misc. Parts
LED’s (light emitting diodes) must be installed according to the silk screen pattern on the board. In
looking at an LED you will notice a flat spot on one side of the LED:
Step
Instructions
TR24
19
Install the 5v linear regulator LM7805CT at
location IC2 forming the leads as indicated
below. Fold the pins over the shaft of a small
screwdriver to create smooth bends. Apply an
even layer of heat sync compound on the back
of the regulator and after inserting the leads into
the proper holes, secure
the IC with a 4-40 bolt, #4
lock-washer, and 4-40
nut. Solder and clip
leads.
20
Install the bridge rectifier at location IC5. Solder
and clip leads as necessary.
Note: this part has a specific orientation. Notice
that one pin on this device has a small + on it
and this corresponds to the plus on the board.
This in the upper right hand corner of IC5 as
shown.
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Step
Instructions
TR24
21
Install the red LED at location PWR. Solder and
clip leads.
Note: These parts have a specific
orientation. The flat side of the LED is
negative and goes toward the flat side
on the silkscreen. The negative
lead goes in the right hand hole for
the PWR LEDs as shown.
22
Install the green LED at location RX TX. Solder
and clip leads.
Note: This part has a specific orientation. The
negative lead goes in the in the upper hole.
23
Install the Yellow LED at location STATUS.
Solder and clip leads.
Note: This part has a specific orientation. The
negative lead goes in the in the upper hole.
24
Install the 4 fuse clips at location F1, and F2.
Solder.
Install Fuses at F1 and F2. Fuses do NOT get
soldered.
Note: The fuses can be used to align the fuse
clips for soldering as long as you do not
overheat them.
25
Install the 1000uf 25V electrolytic
capacitor at location C1. Solder and clip
leads.
Note: Be sure that the (+) lead is installed in
the hole marked with a “+” symbol. The (+)
lead is usually longer than the (-) lead, and
the (-) lead is identified by a black or white
stripe on the capacitor.
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Step
Instructions
TR24
26
Install the 220uf 25V electrolytic capacitor at
location C3. Solder and clip leads. Solder and
clip leads.
Note: This part has a specific orientation just
like C1.
27
Install 2 terminal blocks at the two AC IN
locations ACIN_1 and ACIN_2. Solder.
Note: The terminal blocks must be oriented
facing outward.
28
Install the remaining terminal blocks at locations
CH1 –CH24. Solder.
Note: The terminal blocks must be oriented
facing outward.
29
Install the RJ45 modular jacks at location J1 and
J2. Be careful as the pins are somewhat close
together making alignment difficult. Once the
pins are lined up, pop the jack onto the board.
Solder.
Note: Please inspect the jacks BEFORE
installing to make sure all the pins and wires
inside the connector look straight and nothing is
out of place.
30
Install the 24 Triacs in locations T1 –T24.
Solder and clip leads.
Note: These parts have a specific orientation.
The tab side of the Triac should be towards the
center of the board and the part’s writing nearest
the terminal blocks as illustrated on the silk
screen. T1-12 and T13-24 do face opposite
directions! The thicker line on the silkscreen part
location indicates where the tab/flat side of the
part should go. If you will be adding an optional
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Renard Plus TR24 Controller
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Step
Instructions
TR24
heat sink for the triacs, you want to do so
BEFORE soldering the triacs in place. A heat
sink template is available on www.renard-
plus.com and makes a great triac installation
tool to keep the triacs straight for soldering.
31
Install the Transformer at location TR1
Note: Line up pin 1 marked on the transformer
with the pin 1 on the board silkscreen layout. Be
careful as it is possible to install the transformer
backwards with bad results.
At this point, you should have all your parts installed EXCEPT for the ICs that go in the sockets (or
will be soldered in later). You are now ready to do some power tests to make sure the board
power supply is working properly. Details are in the following section “Initial Testing”.
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Renard Plus TR24 Controller
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3.3.7 Initial Testing
At this point you have completed a majority of the assembly of the board and you should gently
clean the board of any residue and inspect for solder bridges or cold solder joints. What you are
looking for are any solder bridges especially around the IC’s and other closely spaced parts, or
pins that are not fully and cleanly soldered.
If you have any of the IC’s (IC1, IC3, IC4, M1-M24) installed –remove them now.
Connect a line cord (either 115v or 230v AC) to the “line in” terminal ACIN-1 (the one toward
closest to the CH1 connector location.
Warning
High Voltages Present
When you plug in the controller, verify the power LED lights up. If you see lights, use your DMM
and verify you have 5 volts DC between the 5V TP and the GND TP (near the lower left corner of
the PIC). Next, verify you have 5 volts DC between pins 11 (Vdd) and 12 (GND) on the PIC
socket as well as between pins 1 and 4 on the 65LBC179 chip socket.
If the voltage does NOT measure +5 at any of the test spots, remove power and start
troubleshooting. Look for solder bridges around the bridge rectifier, or regulator. Double check
the regulator number to make sure it is what you expect (something like LM7805 or LM340T-5).
Verify the transformer is installed in the correct orientation. Make sure the bridge rectifier is
installed with the correct orientation. Make sure all the pins of the sockets project through the PCB
and are soldered. Check the Voltage Selection straps for the correct selection. Look for cold
solder joints –retouching all solder connections, especially in the power supply area, will often
help solve issues like this.
When power measures properly, disconnect power and finish assembling.
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Renard Plus TR24 Controller
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3.3.8 Install IC’s
Note: Before handling any IC, touch the bottom of the board or use a conductive wrist-strap
attached to the board.
IC’s pins are numbered from 1 to the number of pins counter clockwise with pin 1 being just to the
right of either a notch or dimple on the IC.
Step
Instructions
TR24
32
Install the 40 pin PIC18F4XXX (4520)
microprocessor at IC1.
Note: Pin one goes toward the pin one / notch
on the silkscreen. That is toward the right edge
of the board as shown.
33
Install the 8 pin 65LBC179 RS-485 at IC2.
Note: Pin one goes toward the pin one / notch
on the silkscreen. That is toward the right edge
of the board as shown.
34
Install the 6 pin H11AA1 zero cross output
optocoupler at IC1.
Note: Pin one goes toward the pin one / notch
on the silkscreen. That is toward the bottom
edge of the board as shown.
Note: It is easy to mix up the H11AA1 with the
MOC 3023’s so check the part carefully.
35
Install 24 of the 6 pin MOC3023 optocouplers at
M1 –M24.
Note: Pin one goes toward the pin one / notch
on the silkscreen. That is toward
the left edge on the top group,
and toward the right on the bottom
group as shown. Some MOC
parts indicate pin 1 with a dot
which goes toward the notch on the silkscreen.
Pin 1 of the IC socket is
on the end, closest to
the notch.
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