Ren-T Assembly Instructions: Difference between revisions

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=='''Configurations'''==
==The Board==
[[Image:Ren-T (Top).jpg]]
[[Image:Ren-T (dwg).gif]]
<br>


This board can be assembled and used in various ways. It can be used simply to generate a zero-crossing signal for the Renard8, Renard64 and Ren-C boards (and optionally for some of the other boards), power for the Renard8 board, and/or convert RS232 to RS485 for use with any of the Renard coop boards (including Ren-C).  It can also be built using a number of different transformers (depending on which board is used, and which transformers the builder has on hand).
===Board Versions===
*V2.4 - Has provisions for mounting a dual secondary transformer.  The dual secondary type transformer was later found to be undesirable for generating the Zero Crossing signal.


=='''Selecting a Transformer'''==
*V2.5 - Removed D5 & D6 and pads for the dual secondary transformer


There are several different possible choices of a transformer.  The most basic considerations are the input voltage, the output voltage and output current ratings of the transformer.  In this discussion, primary will refer to the transformers input winding(s) (that are connected to the AC power line), and secondary refers to the output winding(s) of the transformer.
The input voltage of the transformer must be the same as the AC line voltage available in your locale.  You cannot use a 120VAC transformer in a location with 240 VAC power, nor can you use a 240VAC transformer if your local power is 120VAC.  There are some transformers with dual primaries that can be wired up to accept either 120 or 240 VAC, but discussion of how to use these is beyond the scope of this page.
===''Non Center-Tapped Transformer''===
This is a transformer which has effectively one single output winding with two connections (at each end of the output winding).  This is functionally the same as a center-tapped transformer (see the next section) in which the center-tap wire is left dis-connected (by cutting it off or placing a wire-nut or electrical tape over it).
If you use this type of transformer, the output voltage of this type of transformer should be 6.3VAC or 8VAC, and the output wires of the transformer should be connected to here and here on the PCB. (picture to be added).  The effective schematic ends up looking like this after taking into account the diodes which are actually installed:
[[IMAGE:xformer_regular.GIF]]
The waveform across the output of the transformer (pins 5,8) is a sinewave with amplitude 1.41*Vtrans when fully loaded (where Vtrans would be the 6.3V or 8V rated value of the transformer).  The amplitude will be somewhat higher if there is no load on the transformer or just a minimal load.
[[IMAGE:sinewave_nolabel.gif]]
The output of the rectifier circuit (VOUT+ - VOUT-) is a rectified sinewave, as shown below.  The amplitude of the output waveform is (1.41*Vtrans - 2Vf), where Vf is the forward voltage of the diodes (about 0.7V for regular diodes, 0.4V for Schottky diodes).
[[IMAGE:sinewave_rect.gif]]
===''Center-Tapped Transformer''===
This is a transformer which has a single output winding with three connections (one at either end of the winding, and one in the exact middle), in which the middle connection (the center-tap) is to be used.  One disadvantage of this circuit is that the iron and copper in the transformer is only used with 50% effectiveness (compared with the four-diode, non center-tapped circuit) because at any point in time only half of the transformer is supplying current.
If you use this type of transformer (and use the center-tap), the output voltage should be either 12.6VAC or 16 VAC, and the output wires should be connected to here, here (center-tap) and here. (picture to be added).
[[IMAGE:xformer_ct.GIF]]
The waveform across the output of the transformer (pins 5,8) is a sinewave with amplitude 1.41*Vtrans when fully loaded (where Vtrans would be the 12.6V or 16V rated value of the transformer).  The amplitude will be somewhat higher if there is no load on the transformer or just a minimal load.  The voltage between the transformer center-tap and either of the other two legs is 1/2 of this value.
[[IMAGE:sinewave_nolabel.gif]]
The output of the rectifier circuit (VOUT+ - VOUT-) is a rectified sinewave, as shown below.  The amplitude of the output waveform is (1.41*Vtrans/2 - Vf), where Vf is the forward voltage of the diodes (about 0.7V for regular diodes, 0.4V for Schottky diodes).
[[IMAGE:sinewave_rect.gif]]
===''Dual-Secondary Transformer''===
This is a transformer that has two sets of output windings that may be connected either in series or parallel.  An example of this is the Tamura 3FS-412 Transformer that is shown in the schematic below.  This transformer has two output windings, each good for 6.3VAC at 0.5A each.  The output windings can be connected in series to provide 12.6VAC at 0.5A (with an optional center-tap), or in parallel to provide 6.3VAC at 1.0A.  Note that the output windings have polarity, so that care must be taken to avoid creating short circuits by mis-wiring the outputs.
The Ren-T board provides the proper holes so that this Tamura transformer can be soldered onto the board (here, picture to be added).


=='''Assembly'''==
==Board Functions==
The Renard Transformer (Ren-T) board has three basic functions:
:# Generate a Zero Crossing (ZC) signal
:# Convert the RS232 data coming from the computer to RS485 data
:# Provide a voltage that the Renard 8 can use to generate it’s own operating voltage.
<br>
==Schematic Diagram==
[[Image: Ren-T V25 Schematic.jpg | 800px]]


[[Image:Ren-T parts designation.jpg|350 px]]
<br>
==Configurations==
The Ren-T can be built in three basic configurations.  How the Ren-T will be used with other devices will dictate which configuration that should be used.


===Case 1===
==='''CASE 1:''' ===
'''''Connecting PC to first controller without converting to RS485'''''
'''''Connecting PC to first controller without converting to RS485'''''
<br> <br>
[[Image: Ren-T Case 1.gif]]
<br>
In this configuration:
*The RS232 data coming from the computer is not converted on the Ren-T.  By placing the shunts on J1 and J2, the incoming RS232 data on P1 pin 3 is routed to JR1 pin 4.  Also, GND on P1 pin 5 is routed to JR1 pin 5.


:'''1.  Using a Center-Tap Transformer with the Center-Tap connected'''
*The transformer output is applied to diodes D1 & D2 to generate the ZC signal that is applied to JR1 pins 7 & 8.
::* D1, D2, D3, R1, R2, P1, JR1, J1 (shunt), J2 (shunt)


:'''2.  Using a Transformer without a Center-Tap (or a disconnected Center-Tap)
*Ren-T is connected to the serial port or a USB-to-Serial adapter on the controlling computer
::* D1, D2, D3, D5, D6, R1, R2, P1, JR1, J1 (shunt), J2 (shunt)
<br>
This configuration is fine in situations where the computer, Ren-T and controller board are all in relative close proximity.  RS232 data lines are usually only good for distances up to about 50 feet.


===Case 2===
<br>
'''''Connecting one Controller to the next (RS485 pass-through) '''''
----
<br>
==='''CASE 2:''' ===
'''''Connecting one Controller to the next (RS485 pass-through)'''''
<br> <br>
[[Image: Ren-T Case 2.gif]]
<br>
In this configuration:
*RS485 data coming out of one controller board is routed to another controller board via the Ren-T.  Nothing is done to the data signal on the Ren-T, it is just routed from JR2 pins 4 & 5 straight to JR1 pins 4 & 5. 


:'''1. Using a Center-Tap Transformer with the Center-Tap connected '''
*The shunts on J1 and J2 are not installed. 
::* D1, D2, D3, R1, R2, JR1, JR2 (omit shunts)


:'''2. Using a Transformer without a Center-Tap (or a disconnected Center-Tap)'''
*The transformer output is applied to diodes D1 & D2 to generate the ZC signal that is applied to JR1 pins 7 & 8.
::* D1, D2, D3, D5, D6, R1, R2, JR1, JR2 (omit shunts)


===Case 3===
*Ren-T is not connected to the controlling computer
'''''Connecting PC to first controller, converting to RS485 in the process '''''


:'''1. Using a Center-Tap Transformer with the Center-Tap connected'''
::*D1, D2, D3, D4, D7, R1, R2, P1, JR1, U1, U2, U3, C1, C2 (omit shunts)


:'''2. Using a Transformer without a Center-Tap (or a disconnected Center-Tap)'''
This configuration is ideal for situations where it is desirable to connect the output of one controller to the input of a second controller that is a good distance from the first. The RS485 data signal is good for up to 4,000 feet but It is not possible to send the ZC signal over large distances without losing signal integrity.  By placing a Ren-T near the input of the second controller board, you create a new ZC signal and use the RS485 data signal coming from the first controller board.
::*D1, D2, D3, D4, D5, D6, D7, R1, R2, P1, JR1, U1, U2, U3, C1, C2 (omit shunts)


=='''BOM'''==
<br>
----
<br>
==='''CASE 3:''' ===
'''''Connecting PC to first controller, converting to RS485 in the process'''''
<br> <br>
[[Image: Ren-T Case 3.gif]]
<br>


Mouser part#'s listed.
Most widely used configuration


*'''U3''' ~ 1 -  595-UA78L05ACLPRE3  - Standard 5V, 100mA Fixed Pos Voltage Regulator  
In this configuration:
*RS232 data coming from the controlling computer is converted to RS485 data.  The RS485 data is then routed to JR1 pins 4 & 5.  


*'''U2''' ~ 1 -  837-ISL81487EIP      -  RS-485/422 Interface ICs 5V TXRX ESD
*The shunts on J1 and J2 are not installed. 


*'''U3''' ~ 1 -  595-SN75C189AN  -  RS-232 Interface ICs Quad Low Pwr
*The transformer output is applied to diodes D1 & D2 to generate the ZC signal that is applied to JR1 pins 7 & 8.


*'''C1''' ~ 1 - 140-XRL16V10-RC    -  Radial Electrolytic Capacitors 16V 10uF 20% 
*The transformer output is also applied to diodes D4 & D7 as input into the voltage regulator U3.  U3 produces the operating voltage for U1 and U2


*'''C2''' ~ 1 - 140-XRL16V470-RC  - Radial Electrolytic Capacitors 10V 470uF 20% 
*Ren-T is connected to the serial port or a USB-to-Serial adapter on the controlling computer


*'''D1, D2, D4, D5, D6, D7''' ~ 6* -   625-1N5819-E3    -   Schottky Rectifiers Vr/40V Io/1A  ***(''Different configs do not require 6 diodes!'')*** 
<br> <br>
----
<br>


*'''D3''' ~  1 -  604-WP7104GT  ***('''''or''''')***  604-WP7104IT -  LED  >  GT = Green ~  IT = Red 
=='''Selecting an Alternative Transformer'''==


*'''R1''' ~ 1 - 291-1K-RC - 1/4W 5% Carbon Film Resistors 1Kohms 0.05   
There are several different possible choices of a transformer.  The most basic considerations are the input voltage, the output voltage and output current ratings of the transformer. In this discussion, primary will refer to the transformers input winding(s) (that are connected to the AC power line), and secondary refers to the output winding(s) of the transformer.


*'''R2''' ~ 1 - 291-750-RC - 1/4W 5% Carbon Film Resistors 750ohms 0.05 (LED resistor)
The input voltage of the transformer must be the same as the AC line voltage available in your locale. You cannot use a 120VAC transformer in a location with 240 VAC power, nor can you use a 240VAC transformer if your local power is 120VAC.  There are some transformers with dual primaries that can be wired up to accept either 120 or 240 VAC, but discussion of how to use these is beyond the scope of this page.


*'''J1, J2''' ~ 2 -  538-22-03-2021  -  .100 K.K. Connectors VERT PCB HDR 2P TIN PLATING 
The preferred design uses a center-tapped transformer. This is a transformer which has a single output winding with three connections (one at either end of the winding, and one in the exact middle), in which the middle connection (the center-tap) is to be used. One disadvantage of this circuit is that the iron and copper in the transformer is only used with 50% effectiveness because at any point in time only half of the transformer is supplying current.


*2 - 649-65474-002LF    -  Bergcon Connectors SHUNT TIN
The transformer output voltage should be either 12.6VAC or 16 VAC, and the output wires from the transformer should be connected as shown here.


*'''P1''' ~ 1 - 152-3409      -  D-Sub Connectors 9C R/A PCB RECPT 
[[IMAGE:Xformer_conn2.gif]]


*'''JR1, JR2''' ~ 2 - 571-5520251-4    -  Modular Jacks 8/8 SIDE ENTRY
The effective schematic (taking into account the parts which are actually installed) is here:


'''''Optional Parts'''''
[[IMAGE:Xformer_ct.gif]]


*1 - 693-CMF1.1111.12    -    Power Entry Modules 2.5A C8 INLET PCB MT (requires the AC cord below, or an older style 'laptop' power cord. Check the data sheet for a picture.)
The waveform across the output of the transformer (pins 5,8) is a sine wave with amplitude 1.41*Vtrans when fully loaded (where Vtrans would be the 12.6V or 16V rated value of the transformer). The amplitude will be somewhat higher if there is no load on the transformer or just a minimal load. The voltage between the transformer center-tap and either of the other two legs is 1/2 of this value.


*1- 173-21114-E    -  AC Power Cord 10' 2W 18AWG BK
[[IMAGE:sinewave_nolabel.gif]]


*1 - 571-3902613    -  IC Sockets 14P ECONOMY TIN
The output of the rectifier circuit (VOUT+ - VOUT-) is a rectified sinewave, as shown below.  The amplitude of the output waveform is (1.41*Vtrans/2 - Vf), where Vf is the forward voltage of the diodes (about 0.7V for regular diodes, 0.4V for Schottky diodes).
*1 - 571-3902612    -   IC Sockets 8P ECONOMY TIN


[[IMAGE:sinewave_rect.gif]]


=='''Related Links'''==


'''''TRANFORMER CHOICES'''''
[[Ren-T PCB Assembly Instructions | Ren-T PCB Assembly Instructions]]
 
41PG300  -   12.6CT .3A
 
838-3FS-412    - 12.6VAC  6.0VA Single Primary
 
838-3FD-412  - 12.6VAC  6.0VA Dual Primary  ('''for 230V INPUT!''')
 
*The transformers listed are not the only ones that can be used. They are what was used during the design and testing and are direct fits for the pads of the PCB.




=='''Schematic'''==
[[Category:Renard]]
[[Image:Ren-T schematic.gif]]
[[Category:Ren-T]]
[[Category:Ren-C]]
[[Category:DIYC Index]]

Latest revision as of 03:14, 29 January 2011

The Board


Board Versions

  • V2.4 - Has provisions for mounting a dual secondary transformer. The dual secondary type transformer was later found to be undesirable for generating the Zero Crossing signal.
  • V2.5 - Removed D5 & D6 and pads for the dual secondary transformer


Board Functions

The Renard Transformer (Ren-T) board has three basic functions:

  1. Generate a Zero Crossing (ZC) signal
  2. Convert the RS232 data coming from the computer to RS485 data
  3. Provide a voltage that the Renard 8 can use to generate it’s own operating voltage.


Schematic Diagram


Configurations

The Ren-T can be built in three basic configurations. How the Ren-T will be used with other devices will dictate which configuration that should be used.

CASE 1:

Connecting PC to first controller without converting to RS485


In this configuration:

  • The RS232 data coming from the computer is not converted on the Ren-T. By placing the shunts on J1 and J2, the incoming RS232 data on P1 pin 3 is routed to JR1 pin 4. Also, GND on P1 pin 5 is routed to JR1 pin 5.
  • The transformer output is applied to diodes D1 & D2 to generate the ZC signal that is applied to JR1 pins 7 & 8.
  • Ren-T is connected to the serial port or a USB-to-Serial adapter on the controlling computer


This configuration is fine in situations where the computer, Ren-T and controller board are all in relative close proximity. RS232 data lines are usually only good for distances up to about 50 feet.



CASE 2:

Connecting one Controller to the next (RS485 pass-through)


In this configuration:

  • RS485 data coming out of one controller board is routed to another controller board via the Ren-T. Nothing is done to the data signal on the Ren-T, it is just routed from JR2 pins 4 & 5 straight to JR1 pins 4 & 5.
  • The shunts on J1 and J2 are not installed.
  • The transformer output is applied to diodes D1 & D2 to generate the ZC signal that is applied to JR1 pins 7 & 8.
  • Ren-T is not connected to the controlling computer


This configuration is ideal for situations where it is desirable to connect the output of one controller to the input of a second controller that is a good distance from the first. The RS485 data signal is good for up to 4,000 feet but It is not possible to send the ZC signal over large distances without losing signal integrity. By placing a Ren-T near the input of the second controller board, you create a new ZC signal and use the RS485 data signal coming from the first controller board.



CASE 3:

Connecting PC to first controller, converting to RS485 in the process


Most widely used configuration

In this configuration:

  • RS232 data coming from the controlling computer is converted to RS485 data. The RS485 data is then routed to JR1 pins 4 & 5.
  • The shunts on J1 and J2 are not installed.
  • The transformer output is applied to diodes D1 & D2 to generate the ZC signal that is applied to JR1 pins 7 & 8.
  • The transformer output is also applied to diodes D4 & D7 as input into the voltage regulator U3. U3 produces the operating voltage for U1 and U2
  • Ren-T is connected to the serial port or a USB-to-Serial adapter on the controlling computer




Selecting an Alternative Transformer

There are several different possible choices of a transformer. The most basic considerations are the input voltage, the output voltage and output current ratings of the transformer. In this discussion, primary will refer to the transformers input winding(s) (that are connected to the AC power line), and secondary refers to the output winding(s) of the transformer.

The input voltage of the transformer must be the same as the AC line voltage available in your locale. You cannot use a 120VAC transformer in a location with 240 VAC power, nor can you use a 240VAC transformer if your local power is 120VAC. There are some transformers with dual primaries that can be wired up to accept either 120 or 240 VAC, but discussion of how to use these is beyond the scope of this page.

The preferred design uses a center-tapped transformer. This is a transformer which has a single output winding with three connections (one at either end of the winding, and one in the exact middle), in which the middle connection (the center-tap) is to be used. One disadvantage of this circuit is that the iron and copper in the transformer is only used with 50% effectiveness because at any point in time only half of the transformer is supplying current.

The transformer output voltage should be either 12.6VAC or 16 VAC, and the output wires from the transformer should be connected as shown here.

The effective schematic (taking into account the parts which are actually installed) is here:

The waveform across the output of the transformer (pins 5,8) is a sine wave with amplitude 1.41*Vtrans when fully loaded (where Vtrans would be the 12.6V or 16V rated value of the transformer). The amplitude will be somewhat higher if there is no load on the transformer or just a minimal load. The voltage between the transformer center-tap and either of the other two legs is 1/2 of this value.

The output of the rectifier circuit (VOUT+ - VOUT-) is a rectified sinewave, as shown below. The amplitude of the output waveform is (1.41*Vtrans/2 - Vf), where Vf is the forward voltage of the diodes (about 0.7V for regular diodes, 0.4V for Schottky diodes).

Related Links

Ren-T PCB Assembly Instructions

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