64 Channel Olsen 595 Controller Assembly Instructions

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Introduction

Congratulations, you have just received the newest 595 design light controller PCB. It provides on and off control. Dimming is not supported. Read all of the instructions prior to starting assembly.

Safety Notes

A small note about safety. Be sure to follow all directions and never modify the controller design. If you are unsure of anything about this product STOP and ask someone who is experienced in electronics assembly for assistance.

The Power Supply

First and foremost is the power supply. No matter how much attention you pay into building your new lighting controller if there is no power it will not work. This controller requires a 5vdc FILTERED and REGULATED supply to power the integrated circuits. There are two ways to get 5vdc power to the controller...

Power Option A

The first is through the P1 connector. It is a 2 pin connector (538-70543-0001). When facing the board from the signal input jack(RJ45 labeled “IN”) the positive pin is on the left of the P1 connector and the ground pin is on the right.

Power Option B

The 2nd way to get the required 5vdc into the board is through the input RJ45 jack. If you choose this route the positive must come into pin #1 and the ground to pin #3 of the “IN” RJ45 jack. The current of the power supply will be determined later on in these instructions. P2 is a secondary power input if you need a voltage other than 5vdc to run your SSRs or if you want a separate supply for them. It is not necessary to utilize P2.

Parallel Port

In this design the Parallel port is utilized for the data signals. There are 4 pins in the parallel port you need to locate. They are pins 1, 2, 14 and any one of pins 18-25. Pin 1 from the parallel port must be connected to pin 5 of the “IN” RJ45 connector. Pin 2 of the parallel port must be connected to pin 8 of the “IN” RJ45 connector. Pin 14 of the parallel port must be connected to pin 7 of the “IN” RJ45 connector. Finally any one of pins 18-25 must be connected to pin 3 of the “IN” RJ45 connector. The above listed connections can be made through a custom cable or the utilization of a DB25 - RJ45 adapter with the appropriate terminations along with a standard network cable.

Board Options

There are a few options you need to consider.

Daisy Chain Power

If you are running 2 or more of these controllers you will have to decide if you want to “daisy chain” the power from board to board or if you will provide separate external supplies for each board. If you want to “daisy chain” the power through the “OUT” RJ45 connector you will need to install a shunt at J1.

SSR Power

Next determine the Solid State Relay requirements you have. If you are using 5v SSRs then you can use the main power supply to provide power to them. You may decide to use a separate power supply for the SSRs. You may be using SSRs that require a different voltage. In either case you will need to install jumpers 2-9. Each jumper will determine the power source for the SSRs in 8 channel banks. Channels 1-8, output A and B, are on jumper 2, channels 9-16, output C and D, are on jumper 3 and so on. A shunt placed in positions 1 and 2 of J2 - J9 will provide the SSRs with 5vdc power from the main supply for the integrated circuit chips. A shunt placed in positions 2 and 3 of J2 - J9 will provide power for the SSRs from the secondary source connected to P2.

LEDs

Now you have to decide if you want to install the LEDs. There are 65 of them, 64 green and 1 red. The 1 red LED is located at L1. It is a 5vdc ”power indicator”. If there is 5vdc supplied to the board then the LED will glow. If you decide to install this LED you will need to install R1 as well. The value of R1 is determined by the LED rating. I have included the LED and appropriate resistor in the parts list. The other 64 LEDs are “channel output indicators”. They indicate the channel is active. If you decide to install the 64 channel output LEDs you will also need the resistor packs at R2 - R9 of the appropriate value. I have included the parts numbers in the parts list.

IC Sockets

The last option is sockets for the M74HC595 and ULN2803A chips. I highly suggest utilizing the sockets in the parts list. The reason is two fold, there is no chance of overheating the chip during soldering and if a chip needs replacement it is as simple as pulling it out and putting in a new one.

Output Connectors

The outputs are broken into groups of 4 channels. Connectors A-P have 4 channels each. A is channels 1-4, B channels 5-8 and so on. Each output RJ45 also has a constant power and ground output. The A-P RJ45 pinouts are as follows: Pin 1 is power, Pin 2 is the 1st channel output in the connector, Pin 4 is the second channel in the connector, Pin 6 is the third channel in the connector, Pin 7 is the ground and Pin 8 is the 4th channel in the connector, ex connector A pin1 is power, Pin 2 is channel 1, Pin 4 is channel 2, Pin 6 is channel 3, Pin 7 is ground and Pin 8 is channel 4. Connector B will output channels 5-8. The output signals are “sinked” and designed to be utilized with matching SSRs. This means the SSRs are supplied with a constant power source and the grounds are switched on and off.

Power Supply Current Requirements

Your 5vdc power supply current requirements can now be determined. You will need to calculate the total current draw, optional LEDs and SSR current. If you install all 65 LEDs as I listed in the parts list with the resistor packs listed you will need a minimum of 5vdc 390ma just to power the LEDs alone. This figure is for 1 595 control board and does not include the SSR power requirements that have been chosen to be powered by the main supply at P1, so add that to the 390 and you come up with the absolute minimum rating. I would suggest at least 10-20% more. All the calculations in these directions are based on a 5vdc supply and shunts placed in position 1 and 2 at J2 - J9.

Assembly

As you install each component, cut the leads on the bottom of the board that extend past the solder joint.

Board Labels

The assembly of the components is relatively straight forward. The boards are labeled for the IC chips, resistors, capacitors, LEDs, jumper terminals and connectors. The LEDs and IC chips must be installed in the proper orientation or they may burn up or not work. The LEDs either have a flat side or one lead is shorter than the other. In either case the negative lead is indicated by the one closest to the flat side or the shorter lead. This negative lead must be placed through the square pad. The IC chips have a little circle or marking on the top of the chip closest to Pin 1. If the chip is positioned so the marking is on the left side then Pin 1 is on the bottom left corner. The IC chip must be installed with Pin 1 in the square pad.

Passive Components

Assembly should start with the passive components. They are usually smaller and easier to place first. This is the path we will follow. Place the capacitors (581-SA105E1042) at C1 and solder them in, there are 8 of them. Next place the resistor (660-CF1/4C471J) at R1 and solder, if you are installing the red LED (604-WP7104EC) at L1.

Integrated Circuits

Next we will install the 16 and 18 pin sockets (571-3902614 and 571-3902615) if you purchased them. If you did not use the sockets, install the M74HC595 and ULN2803A chips now.

LEDs

Next will be the installation of the LEDs (604-WP7104GC), if you are using them followed by the installation of the resistor packs at R2 - R9. The resistor packs will have a dot above pin 1, this pin should be installed into the square pad.

Power Connectors

Now install both the P1 and P2 power connector (538-70543-0001). The power connectors do not have a polarity, just be sure you install them so the polarity of the socket matches the polarity of the matching plug. Next install the 2 pin header (538-22-03-2021) at J1 and the 3 pin headers (538-22-03-2031) at J2 - J9. Install the 18 RJ45 jacks (571-5202514). Finally, if you have utilized the 16 and 18 pin sockets, install the M74HC595 and ULN2803A chips.

Notes on Soldering

A few points about soldering. You need a small tip on a soldering iron. A soldering gun will not work here, it is too big and too hot. A 20w soldering iron will work fine. I also recommend .032 rosin core solder. Large sizes of solder will place too much solder on the pad and risk the chance of bridging pads and shorting out the board. A little goes a long way but too little solder will leave a weak connection. To solder, turn on the soldering iron and give it ample time to heat up completely. A damp sponge is nice to have close by so you can clean off any excess solder off the tip of the soldering iron. All soldering on this board is done on the bottom. After the component leads are placed through the pads touch the tip of the iron at about a 45 degree angle. Make sure the tip touches both the pad and lead you want to solder. Now touch the component and pad with the solder and the solder will melt. Only use as much solder as will make the connection, too much is no good.


Updated 02/12/2007

64 Channel Olsen 595 Controller Parts List


Other Troubleshooting

Erratic control behavior --> Ensure that the port settings in the BIOS on your computer are set to EPP

Ensure chips are inserted into sockets fully and in the correct orientation


If you find that your 595 does not work after going through this WIKI or applyng the previous Other Troubleshooting fixes, try this...


1) Remove power from board

2) Remove all the chips from the board (I'm assuming that you used sockets since you have swapped chips).

3) Check pin 8 on all 595 sockets, all should be shorted to each other and ground pin of input power connector and nothing else

4) Check pin 16 on all 595 sockets, all should be shorted to each other and 5 VDC input power pin and nothing else

5) Check pin 12 on all 595 sockets, all should be shorted to each other and pin 7 of RJ45 IN & RJ45 OUT connectors and nothing else

6) Check pin 11 on all 595 sockets, all should be shorted to each other and pin 5 of RJ45 IN & RJ45 OUT connectors and nothing else

7) Check pin 14 on first 595 socket, it should be shorted to pin 8 of RJ45 IN connectors and nothing else


If all is good so far, keep going


8 ) Apply power to the board, check pin 16 of all the 595 sockets for 5 VDC (should be a given if the above checks were good)

9) Remove power from board and install the first set of chips (1 595 and 1 ULN2803). If possible, use a set from a known working Olsen.

10) Apply power and try running your sequence again.

If it works, then repeat steps #9 & #10 again with the next set of chips. Continue this until you find a set that causes this to stop working.

If you have a failure then focus you attention of the solder connections for the set that caused the failure.