Renard-595 Converter: Difference between revisions

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== Introduction ==
== Introduction ==
The Renard-595 Converter (aka Ren-C) board is designed to allow the 64-Channel Olsen 595 and GRINCH controller boards to be controlled through the serial port of a PC.  The Ren-C also adds a 192-level dimming capability to these boards.


[[Image:Board 3D REN C sm.jpg]]


The current 595-style (including the GRINCH) controllers are designed to turn display lights on and off under computer control. They are connected to the parallel port of the controlling PC and have the capability of being daisy-chained together. This daisy-chain configuration allows up to approximately 1024 channels to be controlled through one parallel port.  This large channel count is highly desirable by many users but the lack of a dimming capability frustrates many others.  Previous attempts to add a dimming capability to these systems resulted in using eight on/off channels to create one channel with dimming capability.  The complexity of the design and cost in resources kept it from being widely used, thus the need for a different solution and the birth of the Ren-C.


'''Mockup of the REN-C'''
<br>


==The Board==
[[Image:Ren-C (top).jpg]]


The Renard-595 Converter (aka REN-C) is a proposed board that will allow a 64-Channel Olsen 595 Controller to be controlled through the serial port on a PC, and to be dimmed (this PCB would also work with the 64-Channel Grinch controller).  This board is currently under development, and there is no guarantee that this development will be completed.
<br>


The existing 595 controllers (including the Grinch design) are designed to turn display lights on and off under computer control.  They are to be connected to a PC parallel port, with the possibility of daisy-chaining multiple controllers together.  This allows up to around 1024 channels (circuits) to be controlled through one parallel port.  There is a design that allows eight of these channels to be bundled together to form one dimmer control circuit, but this is relatively expensive and fairly rare.  The most common versions of this controller provides simple on-off control, without any dimming capability.
[[Image:Ren-C (dwg).jpg]]


The Renard-595 converter is designed for exclusive use with the 64-channel 595-style controller.  The Converter has one serial input link (RS232 or RS485) that receives light control packets from the PC, one serial output link for sending data to another daisy-chained converter, and one port for connecting to a single 595-style controller.  The 64 channels on this controller (previously on-off only) can now be dimmed, provided that the SSRs on this 595-controller have the capacity to be dimmed over 192 brightness levels.  This setup (converter plus 64-channel 595-style controller plus 64 SSRs) now provides 64 dimmable channels.
<br>


The total number of channels (circuits) that can be provisioned on each PC port (serial port or USB-serial adapter port) depends on the baud rate and on the desired update rate.  A typical number would be 288 channels, based on a 57600 baud rate and a 100 ms update period (576 channels if a protocol change is made or if certain dimmer levels are avoided).  These controllers can be used by themselves, or freely intermixed with Renard controllers on the same serial port, as long as the baudrate is the same on all of the controllers.  Here are two possible setups, one simple and one complex:


<tt>
==Circuit Diagram==
PC (serial port 1) -> Converter --> 64-channel 595 controller (dimmable)
The schematic diagram can be found [http://www.doityourselfchristmas.com/wiki/images/e/ec/Protel_Schematic_V2.0.2.pdf here].


PC (parallel port 1) --> 595 controller (non-dimmable) --> 595 controller (non-dimmable)
The PCB diagram can be found [http://www.doityourselfchristmas.com/wiki/images/f/fb/Multilayer_Composite_Print_V2.0.2.pdf here].
    (parallel port 2) --> 595 controller (non-dimmable)
    (USB port 1) --> (USB->serial adapter) -> Renard8
                                                  |
                                                  V
                                              Converter --> 64-channel 595 controller (dimmable)
                                                  |
                                                  V
                                              Renard64 (64 dimmable channels)
                                                  |
                                                  V
                                              Converter --> 64-channel 595 controller (dimmable)
</tt>
The configuration can be as simple as just one Converter and one 595 controller. The allowable setups also depend on the capabilities of the software in the controlling computer (PC). The above example will work with vixen, taking advantage of its capability to drive multiple I/O ports on the PC.


== Technical and Build Information ==
'''Connectors'''
:* '''To 595 In (JP1)''' –  Provides the Data, Clock and Strobe signals to the 595/GRINCH controller.  Also, provides the Ren-C an operating voltage from the 595/GRINCH controller.
:* '''From 595 Out (JP2)''' –  Brings the output of the shift-register on the 595/GRINCH board back to the Ren-C to enable PWM operation.  This cable can be omitted if PWM operation is not needed/desired.


=== Schematic ===
:* '''RS IN (JP4)''' – RS232/RS485 incoming data and ZC signals from an up-stream controller board or controlling PC.


[http://christmasinshirley.com/wiki/images/0/09/Protel_Schematic_V2.0.1.pdf Circuit Diagram 2.0.1]
:* '''RS OUT (JP5)''' – RS232/RS485 outgoing data and ZC signals for downstream controller boards.
'''IC Chips'''
:* '''U1''' – RS232/RS485 Receiver/Transmitter
:* '''U2''' – Quad NOR gate
:* '''U3''' – PIC16F627A Microcontroller (the brain of the Ren-C)


=== Connectors ===
'''Diagnostic LEDs'''
:* '''D3''' Heartbeat – Blinks on/off at the rate of the ZC signal
:* '''D4''' Overrun – Indicates an data overrun error in the usart of the PIC
:* '''D5''' Framing – Indicates a data framing error in the usart of the PIC
:* '''D6''' Power – Lit whenever power is applied to the board
:* '''D7''' Rx – Lit whenever RS232/RS485 data is received by the PIC


The two RJ45 connectors on the right side of the schematic are used to connect to the 595 board, providing power to the Ren-C board as well as connecting various signals on the boards.  JP1 is the output connector, and must always be present.  JP2 is used to bring the output of the shift-register on the 595 board back to the controller to enable PWM operation (the cable can be omitted if PWM operation is not needed). Some of the signals on this board are fairly high-speed (2.5 MHz), and so the cables between the Ren-C board and the 595 controller should be a short as possible, on the order of 6" or so.
'''Headers'''
:* '''JP3''' – 4-pin connector that provides an alternate method for bringing the ZC signal and operating voltage (5 VDC) onto the board.


The RJ45 connectors on the left side of the board are used to bring RS232/RS485 input signals from the up-stream board  (JP4) and connect the output signals to downstream boards (JP5).  In addition, the zero-crossing signal can be brought into the board through pins 7/8 of JP4 (if Q1 and R9 are installed).  A schematic of a sample circuit for generating the zero-crossing signal is shown in the [[Renard Connection Instructions#Ren-T (Transformer Board) | Renard Connection Instructions]].
:* '''JP6''' - 6-pin connector that can be used to program the PIC in-circuit with either a PicKit2 Programmer (DV164120 or PG164120) or the bare programmer from PicKit1 (PG164101).


JP6 is a 6-pin connector that can be used to program the PIC in-circuit with either a PicKit2 Programmer (DV164120 or PG164120) or the bare programmer from PicKit1 (PG164101).
'''Test Points'''
:* '''TP1''' – Clock Out
:* '''TP2, TP5''' – PWM Reset In
:* '''TP3''' – Data Out
:* '''TP4''' – Strobe Out


JP3 provides an alternate method for bring the zero-crossing signal into the board, as well as an alternate method of providing 5V DC power to the boards (Ren-C plus 595/Grinch).
==Firmware==
:The PIC (U3) must be programmed with the latest firmware for the Ren-C to operate properly.  The firmware can be found [[Renard Firmware#Firmware for Ren-C | here]].


=== BOM ===


The items here are all very preliminary.  In some cases parts that were purchased for previous projects, so there may be better alternatives that haven't been considered.  Also, the Reference Designators may change before the board goes to fab.
==Connection==


<pre>
:Some of the signals on the Ren-C are fairly high-speed (2.5 MHz), so the cables between the Ren-C board and the 595/GRINCH controller should be as short as possible.  Cable length should not exceed 6".  
Qty    Mouser P/N          Ref. Des.                  Description and comments
1    815-AB-20-B2        Y1                20.000 MHz Crystal, HC49U case
2    581-SA102A220JAR    C1,C2            22 pf, 200V NPO Axial Ceramic Capacitors (subject to change)
2   581-SA105E104MAR    C3,C5            .1 uF, 50V, Z5U Axial Ceramic Capacitors (to be verified)
1    140-XRL10V10-RC    C4                10 uF, 10V, Radial Aluminum Electrolytic Cap
5    604-WP7104GT        D3-D7            Green Transparent LED (T1)
1    595-SN65LBC179P    U1                RS485 Receiver/Transmitter (DIP8)
1    511-M74HC02        U2                Quad 2-Input NOR Gate (DIP14) (maybe replaced with CD4001???)
1    579-PIC16F627A-I/P  U3                PIC (to be programmed by user)
2    271-1K-RC          R4,R5            Resistor, 1K, 1/4W
2    271-10K-RC          R8,R9            Resistor, 10K, 1/4W
3    271-27K-RC          R2,R6,R7          Resistor, 27K, 1/4W
1    271-120-RC          R3                Resistor, 120, 1/4W (maybe needs to change to 1% tolerance)                   
1    652-4610X-2LF-470  RP                Resistor Network, 470, 10-Pin SIP, Isolated Resistors     
1    78-1N5229B          D1                Diode, Zener, 4.3V, 0.5W
  1    78-1N5239B          D2                Diode, Zener, 9.1V, 0.5W
4    571-5520251-4      JP1,JP2,JP4,JP5  Modular Jack, Right-Angle, 8-8 
1    512-2N3904TA        Q1                Transistor, NPN, small signal


Optional
Qty
1    575-199318          U3                18 Pin DIL socket
1    575-199314          U2                14 Pin DIL socket
1    575-199308          U1                08 Pin DIL Socket
</pre>


There is no part number given for JP3 and JP6 because they are often built by cutting sections of a break-away connector, such as 571-41032390 (JP3 is used as an alternate method of supplying the zero-crossing signal and power to the board, JP6 is for use with some of the PicKit Programmers). R1 is not need to be installed unless pin 3 of JP3 is to be used as an alternate source of zero-crossing (in this case, R9 probably should not be installed).
'''Typical Single Ren-C Connection'''
  [[Image: Ren-C Layout 1.jpg |800px]] <br>


[[Image:RENC.jpg]]


Here is the first picture of the REN C.  there are still a few components to install, however you can now get a good idea of what a finshed board will look like.


You can see JP3 and JP6 clearly in the picture, as well as the row of DIAG LEDS (power, Rx, Framing, Overrun, heartbeat).
'''Typical Multiple Ren-C Connection'''
[[Image: Ren-C Layout 2.jpg |800px]] <br>


There are also a number of Test Points around the board.TP Gnd is in the bottom right hand corner.


=== Power ===


There are some options on how you can power the RENC board.  First off, you will need 5 VDC, filtered and regulated.
'''Other Connections'''
:*The Ren-C/GRINCH(Olsen 595) combo can be worked into any display configuration with other Renard based controller boards on the same serial port connection.  The main requirement is that the Ren-C/GRINCH(Olsen 595) combo must receive valid Renard protocol formatted channel data and a ZC signal.


'''5V DC'''
'''Limitations'''
:*The number of Ren-C/GRINCH(Olsen 595) combos that can be linked together is limited by the maximum amount of channels that can be achieved based on the baud rate and event interval that VIXEN is using.  More information on this limitation can be found [[Renard#Number of Circuits (Channels)| here]].


Option 1. As the 595/GRINCH board will need to be powered with 5 VDC, you can 'steal' some power from the Controller via the IN RJ45 on the 595/GRINCH.  On both the 595 COOP board and the wjohn GRINCH COOP Board, 5 VDC is connected to a Molex connector labeled J2.  Fitting a shunt to J1, will allow this 5V DC to be routed out the IN RJ45 Socket and to the RENC.


Option 2.  The RENC can be powered directly with it's own 5 VDC supply via the Header JP 3.  There are pins for Vcc and Gnd where 5V DC could be connected.


'''ZC'''
==Powering the Ren-C==
The Ren-C requires an external power source to operate.  This power source must be regulated/filtered 5 VDC.  There are two possible methods of applying power to the Ren-C.
 
'''Power Connections'''
:*'''Option 1''' [Preferred Method]
:::The Ren-C can get it’s operating voltage from the COOP OLSEN 595 or GRINCH controller board that it is connected to.  With this option the COOP OLSEN 595 or GRINCH controller board would be connected directly to the external 5 VDC power supply at either P1 or J2 respectfully.  By placing a shunt on J1, this would allow the 5 VDC to be passed to the Ren-C via the RJ45 IN/OUT connectors on pin 1.
 
:*'''Option 2'''
:::The Ren-C can be powered directly by an external 5 VDC power supply.  This can be accomplished by connecting 5VDC to pin 4 and GND to pin 1 of header JP3.  When using this option you should remove the shunt from J1 of the connected COOP OLSEN 595 or GRINCH controller board to prevent any problems with the associated external power sources.
 
 
There are many options of what to use for the external power source. Some users prefer to use an unused hard drive power connection inside the computer that is being used to run VIXEN. Others prefer to use an old computer power supply that they modify to run as a stand-alone power supply. And there are others that have had success in using wall-warts but care should be used with wall-warts since not all of them provide a regulated/filtered output.
 
 
 
==Zero Crossing Signal Options==
The Zero Crossing (ZC) signal is one of the most difficult signals for new users to understand.  Simply put, ZC is the point at which the AC signal crosses zero volts.  The ZC point needs to be known so that the triacs can be turned on/off at the correct time to achieve a dimming effect.
 
One of the factors that adds to confusion is that the ZC signal is actually different at various points in the overall light control process.  The output of the Ren-T (green trace in picture below) is commonly referred to as a ZC signal.  This raw ZC is not in a suitable form to be used by the PIC.  By applying this signal to base of Q1 on the Ren-C, we will get a new ZC signal (purple trace in picture below) that the PIC can use to for the dimming timing.
 
Now that you understand the ZC signal, you can better decide how you want to get a ZC signal on the Ren-C.
 
:*'''Option 1'''
:::ZC can be generated on the board, by connecting a 9VDC (unregulated and unfiltered) supply to pins #7,8 of the RS IN RJ45 socket. This input signal (green trace in picture below) is a pulsating signal, rising from 0V to 9V and back in time with the AC power line (100 or 120 times per second, depending on your locale). This signal is the normal output from the Ren-T or it can be created using this [[Renard Connection Instructions#Ren-T (Transformer Board)|circuit]].
 
:*'''Option 2'''
:::ZC can be generated on the board, by connecting a 9VDC (unregulated and unfiltered) supply to The "ZC In" pin (#3) of JP3.  This signal (green trace in picture below) can be created using a schematic like this  [[Renard Connection Instructions#Ren-T (Transformer Board)|circuit]].  With this option, you will need to install a 10K resistor in location R1 instead of R9.
 
:*'''Option 3'''
:::ZC can be connected directly to the board, by connecting a ZC Signal (purple trace in picture below),  to the "ZC" pin (#2) of JP3.  With this option, you can remove R1, R9 and Q1.
 
 
[[Image:ZeroCross.gif|center]]
 
==ZC and RENT requirements==
When the REN64XB and RENC were first released, there was an extra board that was made available, the RENT.  The function of the RENT was to provide power and a source of ZC to the controllers.
 
The RENC did not require separate power as it draws 5 V DC from the GRINCH board.  What it does need is a source of ZC.
 
What is ZC?  Zero Cross reference. When dimming, the RENC needs to know the start of the AC signal waveform, i.e. when it crosses over Zero V AC. A small sample of AC voltage is required to obtain the ZC.
 
There are a couple of options.
 
Option 1 - User a small AC stepdown transformer (12.6V CT) and build a simple circuit to rectify the Low V AC to DC.
 
[[Image:Simple RenT Design.jpg | 400px]]
 
Option 2 - Use a small AC stepdown transformer (12.6V CT) and build a OPTOISOLATOR circuit to provide a source of ZC.
NOTE - the diagram should have an H11AA1, not an H11A1 in this circuit.
 
[[Image:Another RENT (H11A1).jpg | 400px]]
 
==Computer Setup==
'''VIXEN Settings'''
:*The Ren-C requires the Renard Dimmer or Renard Dimmer (modified) Plug-In.
::'''Renard Dimmer Plug-In Settings:'''
:::Protocol Version: 1
:::COM1 (or whichever COM port you are connected to)
:::Baud: 57600
:::Parity: None
:::Data bits: 8
:::Stop bits: One
 
 
 
==Related Links==
[[REN-C_PCB_ASSEMBLY_INSTRUCTIONS | Ren-C PCB Assembly Instructions]] <br />
[[The_GRINCH_Controller | The GRINCH Controller]] <br />
[[64 Channel Olsen 595 Controller Assembly Instructions | COOP OLSEN 595 Controller]] <br />
[[Ren-T_Assembly_Instructions|REN-T]]<br />
[[Vixen|VIXEN]]<br />
 
 
[[Category:Ren-C]]
[[Category:Renard]]
[[Category:The Grinch]]
[[Category:Olsen 595]]
[[Category:DIYC Index]]

Latest revision as of 02:02, 19 February 2012

Introduction

The Renard-595 Converter (aka Ren-C) board is designed to allow the 64-Channel Olsen 595 and GRINCH controller boards to be controlled through the serial port of a PC. The Ren-C also adds a 192-level dimming capability to these boards.


The current 595-style (including the GRINCH) controllers are designed to turn display lights on and off under computer control. They are connected to the parallel port of the controlling PC and have the capability of being daisy-chained together. This daisy-chain configuration allows up to approximately 1024 channels to be controlled through one parallel port. This large channel count is highly desirable by many users but the lack of a dimming capability frustrates many others. Previous attempts to add a dimming capability to these systems resulted in using eight on/off channels to create one channel with dimming capability. The complexity of the design and cost in resources kept it from being widely used, thus the need for a different solution and the birth of the Ren-C.


The Board




Circuit Diagram

The schematic diagram can be found here.

The PCB diagram can be found here.

Connectors

  • To 595 In (JP1) – Provides the Data, Clock and Strobe signals to the 595/GRINCH controller. Also, provides the Ren-C an operating voltage from the 595/GRINCH controller.
  • From 595 Out (JP2) – Brings the output of the shift-register on the 595/GRINCH board back to the Ren-C to enable PWM operation. This cable can be omitted if PWM operation is not needed/desired.
  • RS IN (JP4) – RS232/RS485 incoming data and ZC signals from an up-stream controller board or controlling PC.
  • RS OUT (JP5) – RS232/RS485 outgoing data and ZC signals for downstream controller boards.

IC Chips

  • U1 – RS232/RS485 Receiver/Transmitter
  • U2 – Quad NOR gate
  • U3 – PIC16F627A Microcontroller (the brain of the Ren-C)

Diagnostic LEDs

  • D3 Heartbeat – Blinks on/off at the rate of the ZC signal
  • D4 Overrun – Indicates an data overrun error in the usart of the PIC
  • D5 Framing – Indicates a data framing error in the usart of the PIC
  • D6 Power – Lit whenever power is applied to the board
  • D7 Rx – Lit whenever RS232/RS485 data is received by the PIC

Headers

  • JP3 – 4-pin connector that provides an alternate method for bringing the ZC signal and operating voltage (5 VDC) onto the board.
  • JP6 - 6-pin connector that can be used to program the PIC in-circuit with either a PicKit2 Programmer (DV164120 or PG164120) or the bare programmer from PicKit1 (PG164101).

Test Points

  • TP1 – Clock Out
  • TP2, TP5 – PWM Reset In
  • TP3 – Data Out
  • TP4 – Strobe Out

Firmware

The PIC (U3) must be programmed with the latest firmware for the Ren-C to operate properly. The firmware can be found here.


Connection

Some of the signals on the Ren-C are fairly high-speed (2.5 MHz), so the cables between the Ren-C board and the 595/GRINCH controller should be as short as possible. Cable length should not exceed 6".


Typical Single Ren-C Connection


Typical Multiple Ren-C Connection


Other Connections

  • The Ren-C/GRINCH(Olsen 595) combo can be worked into any display configuration with other Renard based controller boards on the same serial port connection. The main requirement is that the Ren-C/GRINCH(Olsen 595) combo must receive valid Renard protocol formatted channel data and a ZC signal.

Limitations

  • The number of Ren-C/GRINCH(Olsen 595) combos that can be linked together is limited by the maximum amount of channels that can be achieved based on the baud rate and event interval that VIXEN is using. More information on this limitation can be found here.


Powering the Ren-C

The Ren-C requires an external power source to operate. This power source must be regulated/filtered 5 VDC. There are two possible methods of applying power to the Ren-C.

Power Connections

  • Option 1 [Preferred Method]
The Ren-C can get it’s operating voltage from the COOP OLSEN 595 or GRINCH controller board that it is connected to. With this option the COOP OLSEN 595 or GRINCH controller board would be connected directly to the external 5 VDC power supply at either P1 or J2 respectfully. By placing a shunt on J1, this would allow the 5 VDC to be passed to the Ren-C via the RJ45 IN/OUT connectors on pin 1.
  • Option 2
The Ren-C can be powered directly by an external 5 VDC power supply. This can be accomplished by connecting 5VDC to pin 4 and GND to pin 1 of header JP3. When using this option you should remove the shunt from J1 of the connected COOP OLSEN 595 or GRINCH controller board to prevent any problems with the associated external power sources.


There are many options of what to use for the external power source. Some users prefer to use an unused hard drive power connection inside the computer that is being used to run VIXEN. Others prefer to use an old computer power supply that they modify to run as a stand-alone power supply. And there are others that have had success in using wall-warts but care should be used with wall-warts since not all of them provide a regulated/filtered output.


Zero Crossing Signal Options

The Zero Crossing (ZC) signal is one of the most difficult signals for new users to understand. Simply put, ZC is the point at which the AC signal crosses zero volts. The ZC point needs to be known so that the triacs can be turned on/off at the correct time to achieve a dimming effect.

One of the factors that adds to confusion is that the ZC signal is actually different at various points in the overall light control process. The output of the Ren-T (green trace in picture below) is commonly referred to as a ZC signal. This raw ZC is not in a suitable form to be used by the PIC. By applying this signal to base of Q1 on the Ren-C, we will get a new ZC signal (purple trace in picture below) that the PIC can use to for the dimming timing.

Now that you understand the ZC signal, you can better decide how you want to get a ZC signal on the Ren-C.

  • Option 1
ZC can be generated on the board, by connecting a 9VDC (unregulated and unfiltered) supply to pins #7,8 of the RS IN RJ45 socket. This input signal (green trace in picture below) is a pulsating signal, rising from 0V to 9V and back in time with the AC power line (100 or 120 times per second, depending on your locale). This signal is the normal output from the Ren-T or it can be created using this circuit.
  • Option 2
ZC can be generated on the board, by connecting a 9VDC (unregulated and unfiltered) supply to The "ZC In" pin (#3) of JP3. This signal (green trace in picture below) can be created using a schematic like this circuit. With this option, you will need to install a 10K resistor in location R1 instead of R9.
  • Option 3
ZC can be connected directly to the board, by connecting a ZC Signal (purple trace in picture below), to the "ZC" pin (#2) of JP3. With this option, you can remove R1, R9 and Q1.


ZC and RENT requirements

When the REN64XB and RENC were first released, there was an extra board that was made available, the RENT. The function of the RENT was to provide power and a source of ZC to the controllers.

The RENC did not require separate power as it draws 5 V DC from the GRINCH board. What it does need is a source of ZC.

What is ZC? Zero Cross reference. When dimming, the RENC needs to know the start of the AC signal waveform, i.e. when it crosses over Zero V AC. A small sample of AC voltage is required to obtain the ZC.

There are a couple of options.

Option 1 - User a small AC stepdown transformer (12.6V CT) and build a simple circuit to rectify the Low V AC to DC.

Option 2 - Use a small AC stepdown transformer (12.6V CT) and build a OPTOISOLATOR circuit to provide a source of ZC. NOTE - the diagram should have an H11AA1, not an H11A1 in this circuit.

Computer Setup

VIXEN Settings

  • The Ren-C requires the Renard Dimmer or Renard Dimmer (modified) Plug-In.
Renard Dimmer Plug-In Settings:
Protocol Version: 1
COM1 (or whichever COM port you are connected to)
Baud: 57600
Parity: None
Data bits: 8
Stop bits: One


Related Links

Ren-C PCB Assembly Instructions
The GRINCH Controller
COOP OLSEN 595 Controller
REN-T
VIXEN

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