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| + | ====== Manual for GCA145 / GCA146 combination ====== | ||
| + | |||
| + | **By Peter Giling** | ||
| + | |||
| + | ===== Hardware remarks. ===== | ||
| + | |||
| + | |||
| + | ===== A fiddle yard needs two limit switches. One at each side. ===== | ||
| + | This could be microswitches, hallsensors or reed switches. \\ | ||
| + | These switches are used for three reasons.\\ | ||
| + | To be able to have an automatic adjustment after the first set-up, for adjustment when the FY is out of position for any reason, and as safety limit switch.\\ | ||
| + | Switches are situated at both ends, beyond the the positions where the first and last rails are in line. \\ | ||
| + | Switches can be connected according [[http://wiki.rocrail.net/doku.php?id=hardware_manual_gca145_version_7-3#connection_of_limit_switches|connection of limit switches]] \\ | ||
| + | Both limit switches are connected to ICSP1.\\ | ||
| + | **Important note:**\\ | ||
| + | It is very important to have a minimum of 30 motor steps between the zero limit switch and the first position.\\ | ||
| + | Also from the last position towards the point where the max limit switch is activated, an absolute minimum of 50 steps or double the settings of menu 5 (coorection steps).\\ | ||
| + | The largest number of these two is the one to choose.\\ | ||
| + | |||
| + | |||
| + | |||
| + | ===== Turntables need only one switch, to detect the zero point ===== | ||
| + | Switches can be connected according [[http://wiki.rocrail.net/doku.php?id=hardware_manual_gca145_version_7-3#connection_of_limit_switches|connection of limit switches]]\\ | ||
| + | Position of this switch should between position 1 and the maximum position.\\ | ||
| + | This switch should be mounted in a way that TT can pass this switch in both directions.\\ | ||
| + | |||
| + | ===== Software settings. ===== | ||
| + | |||
| + | After startup, there are just a few settings preset in the Firmware.\\ | ||
| + | To avoid that adjustment will be a lot of work, the processor can do the important issues automaticly.\\ | ||
| + | For further info about the menus, please refer to chapter MENU.\\ | ||
| + | Each position of a rail has to be determined. And because there is no onfo yet how many steps are needed, the processor needs to find out.\\ | ||
| + | It can only be done if two switches are up and working.\\ | ||
| + | This is done in the following way.\\ | ||
| + | |||
| + | ===== Calculation of all exact positions settings. ===== | ||
| + | |||
| + | Activate menu-settings and select menu 1. Select the maximum positions you need.\\ | ||
| + | The first rail position is always 1.Select menu 9 and change setting to desired control type, see [[http://wiki.rocrail.net/doku.php?id=hardware_manual_gca145_version_7-3#control_types|control types ]].\\ | ||
| + | Cancel menu settings .\\ | ||
| + | {{:gca:j4_jumper_setting.png}}\\ | ||
| + | * Set jumper J4 to ON.\\ | ||
| + | * Choose position 62 on GCA146 and press the selector.\\ | ||
| + | * The motor starts moving backwards to zero switch.\\ | ||
| + | * If it runs in the wrong direction, switch off power immidiately, and swap wires 1 & 2 of the motor in connector J2, and select pos 62 again.\\ | ||
| + | * It should now be running in the right direction, towards zero switch.\\ | ||
| + | * The motor will stop when the zero-switch is activated.\\ | ||
| + | * If control type 1, 2 or 3 is selected, the motor will make another full round, to calculate the amount of steps for a full circle.\\ | ||
| + | * Next, the motor starts running on slow speed towards first rail connection.\\ | ||
| + | * On the right moment , when rails are nicely inline, press selector.\\ | ||
| + | * This position will be stored, display will show 1 and motor continues. Remeber that fine adjustments can be made later.\\ | ||
| + | * Again, when rails are in line, press selector.\\ | ||
| + | * Repeat this until all positions are acknowleged.\\ | ||
| + | * Motor will run back to zero switch and after that returns to position 1.\\ | ||
| + | * After finishing put jumper J4 in OFF position.\\ | ||
| + | |||
| + | ===== Hardware differences between boards MGV145 and GCA145. ===== | ||
| + | |||
| + | Based on experiences and feed-back from many satisfied users (thanks folks !) som minor changes were obsolete at the new batch of PC-boards.\\ | ||
| + | Basicly, everything is made in such a way that Firmware is 00% adapted to both PC-boards.\\ | ||
| + | There are no differences on that issue.\\ | ||
| + | But a few improvements has been made on the GCA145 board :\\ | ||
| + | * 1. +5v and ground on ICSP1 were not compatible with ICSP connectors on boards like GCA50, GCA136 etc. \\ | ||
| + | It is important to realise that it makes a different connection for Hall-sensors or switches for zero and max-limit detection. In this manual a drawing is available for both situations. | ||
| + | * 2. P2 is adapted for setting to maximum current for the motor. More about that in Appendix 3. | ||
| + | * 3. A few resistors were to be soldered at the bottom of MGV145. They are on-board now on GCA145. | ||
| + | * 4. The value of the used relays was rather critical, to make them work. \\ | ||
| + | This was mainly because the specification of the PIC is sometimes a little bit less powerfull than given. \\ | ||
| + | Relays are now driven by transistors, taking away the load from the PIC.\\ | ||
| + | * 5. Eep1. | ||
| + | - On MGV45 it should always be in “ON' position.\\ | ||
| + | - On GCA145 it is no longer in use, do NOT assemble it.\\ | ||
| + | * 6. J4 is a jumper now. It is used to enable (if set to ON) the calculation of all postions. | ||
| + | * 7. A number of leds are provided, to be able to watch several functions. | ||
| + | * 8. Power supply can now go as high as 24 Volt. \\ | ||
| + | This of course if suitable transformer is used. \\ | ||
| + | But with 24 V, the power over C1, and thus at the input of VR2 is way too high. \\ | ||
| + | In that case jumper JP2 can be set , so that VR2 gets power from 24V (pos 1) . \\ | ||
| + | Basicly it is OK to leave jumper JP2 on pos 1, when you are running on 12V, but the minimum should be 10V. \\ | ||
| + | Any lower, jumper JP2 must be set to pos 2.\\ | ||
| + | |||
| + | ===== Led functions. ===== | ||
| + | |||
| + | |||
| + | MGV145 board only has 1 led, which simply shows power on.\\ | ||
| + | GCA145 board has 6 Leds.\\ | ||
| + | | Led1 | Power on | | ||
| + | | Led2 | Bridge power on | | ||
| + | | Led3 | Reverse bridge power on | | ||
| + | | Led4 | Motor running forward | | ||
| + | | Led5 | Motor running reverse | | ||
| + | | Led6 | System ready | | ||
| + | \\ | ||
| + | ===== Fine adjustment of positions ===== | ||
| + | |||
| + | Fine adjustment can be made for each position by activating the menu settings, then select menu 0 , which will display after 1 second the actual position where the FY/TT is on.\\ | ||
| + | Now , with the selector you can fine tune the position, to make the rails perfect in-line.\\ | ||
| + | Cancel the program mode, run the FY /TT to the next position and redo the same procedure for fine adjustment adjust of positions.\\ | ||
| + | |||
| + | |||
| + | ===== Menu. ===== | ||
| + | |||
| + | The program switch, located below the position selector on GCA146, has two positions:\\ | ||
| + | 1) The normal running mode (switch OFF)\\ | ||
| + | 2) The programming mode (switch ON) \\ | ||
| + | The ON position is indicated in display with a dot between the two digits.\\ | ||
| + | This counts for MGV146 pcb, the GCA146 pcb has an additional Led for this indication.\\ | ||
| + | In normal running mode only the actual position of the FY/TT can be selected.\\ | ||
| + | Turn the selector to get a position, and press the selector. FY/TT will start moving according to that.\\ | ||
| + | When a higher position is selected, the motor will stop a little bit further the desired , and then will run backwards after one second.\\ | ||
| + | The amount of steps, of the runback is to be set in menu 5.\\ | ||
| + | This is done to correct the free space in gearing, if applicable. Value can also be set to 0.\\ | ||
| + | If the program switch is set to ON, the display show the menu number for 1 second, and after that the display will show the value of that menu.\\ | ||
| + | Changing this value can be done with the selector. No need for confirmation.\\ | ||
| + | Pressing the selector will put you into the next menu, again showing the menu number first and then the value of it. \\ | ||
| + | ==== List of menus ==== | ||
| + | |||
| + | The available menues are:\\ | ||
| + | === 0) Adjust the actual position of the fiddle yard. === | ||
| + | When turning the selector , the motor will turn backwards or forward step by step, making a very fine adjustment possible.\\ | ||
| + | All changes are stored in internal eeprom.\\ | ||
| + | Please remind not to leave this menu 0 active for a longer time, because the motor is constantly powered on, and will be getting rather warm after some time.\\ | ||
| + | When selecting a next menu, or deactivating the menues, the power to motor will be off.\\ | ||
| + | === 1) Total amount of railpositions. === | ||
| + | Positions are counting from 1.\\ | ||
| + | |||
| + | === 2) The minimum speed. === | ||
| + | |||
| + | Two speed limits are used for the motor., making it possible to make a slow or fast ramp up and ramp down when start en stop moving.\\ | ||
| + | A higher number means longer interval between the motor steps, so a slower movement.\\ | ||
| + | === 3) The maximum speed. === | ||
| + | |||
| + | Same as point 2. \\ | ||
| + | A higher number means a longer interval of timing, so that makes a slower movement.\\ | ||
| + | Depending on motor type and power consumption, mostly the lowest speed setting you can have is 4 or 5.\\ | ||
| + | If the motor makes strange reactions, try a larger number for this speed. \\ | ||
| + | Maximum speed can not be set to a higher value than minimum speed \\ | ||
| + | === 4) Delay of speed change. === | ||
| + | |||
| + | The actual speed from low to high or v.v. is incremented (in microseconds) with this number.\\ | ||
| + | A higher number means faster change.\\ | ||
| + | When minimum and maximum speed are set equal, there will be no change at all.\\ | ||
| + | === 5) Correction steps. === | ||
| + | |||
| + | When FY is running to a higher position, it will make this amount of steps further, and after that run the same steps back .\\ | ||
| + | That option can reduce the influence of any 'slack' in the gear system. If you do not need it, just the better, just set it to zero.\\ | ||
| + | 6) Rail power reverse position.\\ | ||
| + | This only applies to turntables, control type 1..3, where the power of the bridge should be reversed in certain positions, to match the connecting rails.\\ | ||
| + | The setting you do here is the first position, counting from 1, where power should be reversed. \\ | ||
| + | This setting is of no influence in control type 4. It is also possible to disable this function by setting to zero.\\ | ||
| + | === 7) Rail power off at movement. === | ||
| + | |||
| + | The rails can be powered off while moving the bridge. \\ | ||
| + | This is usually an extra safety precaution, specially for Fiddle yards. \\ | ||
| + | But on turntables, where only one train is involved, it might be not so nice to shut off lights of the loc, while moving. \\ | ||
| + | Setting menu 7 to zero, disable the power while moving, setting to 1 will leave power enabled. If reversing power is obsolete, it will be activated after the bridge has come to halt. \\ | ||
| + | === 8) Position match delay. === | ||
| + | |||
| + | After the bridge has reached its position, this will give an extra delay before the indication “system ready” is given to pt 10 of J5.\\ | ||
| + | Also, only after that time, the selector is active again. \\ | ||
| + | It is used if signals are fixed on or besides the FY/TT. \\ | ||
| + | They will have an extra delay before they will be on. The number is in 10th of second, so 50 will be 5 seconds.\\ | ||
| + | === 9) Control type. === | ||
| + | |||
| + | This is the menu to select the way control is made.\\ | ||
| + | Possible settings are:\\ | ||
| + | 1 : turntable control with no shortest way option.\\ | ||
| + | 2 : turntable control with shortest way option. Amount of zero crossings are limited.\\ | ||
| + | 3 : turntable control with shortest way option. No limits in zero crossing.\\ | ||
| + | 4 : Fiddle yard version.\\ | ||
| + | \\ | ||
| + | ===== Manual operating mode ===== | ||
| + | |||
| + | |||
| + | If program switch is off, only the current position can be selected with selector on control panel.\\ | ||
| + | Apart from pos 1 to xx (the max amount of rails) there are two more positions to select.\\ | ||
| + | === 1) Position 63. === | ||
| + | |||
| + | This position will move the FY/TT to the zero-limit switch and after that the will run to position 1.\\ | ||
| + | Now FY/TT is synchronised to position 1.\\ | ||
| + | Display will show position 1 when finished.\\ | ||
| + | === 2) Positon 62. === | ||
| + | |||
| + | This position can only be activated if J4 jumper is set to ON.\\ | ||
| + | See for further instructions: Calculation of all exact position settings.\\ | ||
| + | ===== Computer controlled mode. ===== | ||
| + | |||
| + | |||
| + | There is no setting to get in this mode.\\ | ||
| + | GCA145 simply reacts when new positions are given trough connecter J5 (Position cmd).\\ | ||
| + | On http://wiki.rocrail.net/doku.php?id=gca145-en page, you will find more info about how settings should be made to get this computer control settled.\\ | ||
| + | Rocrail included a complete controlsetup for either Turntable or Fiddle yard.\\ | ||
| + | This setup includes control vie LocoNet, CANBUS, DCC or Motorola.\\ | ||
| + | For the last two a special function decoder GCA174 is available, to be fitted as a piggy back to J5 on GCA145/MGV145.\\ | ||
| + | |||
| + | ===== Imergency / safety switch. ===== | ||
| + | |||
| + | Using GCA145 controller on larger setups with fiddle yard, specially if public is able to approach it, there might be a reason to have some way of emergency stop.\\ | ||
| + | The max limit switch can be used for that.\\ | ||
| + | Numerous ways are available to make some kind of emergency or safety switch.\ | ||
| + | If you need any advice on that issue, please ask peter@phgiling,net.\\ | ||
| + | When max limit switch is activated, either in manual or computer controlled operation, the max limit switch is activated, the motor will stop turning immediately.\\ | ||
| + | On GCA146 display the point between two digits will flash.\\ | ||
| + | The position where the movement was targeted to, is not lost.\\ | ||
| + | Just make security test to see, everything is clear and press select button.\\ | ||
| + | The motor will start again and finish the movement.\\ | ||
| + | ===== Connection of limit switches. ===== | ||
| + | |||
| + | {{:gca:limit_switches_connection.jpg?700}}\\ | ||
| + | |||
| + | ===== Control types. ===== | ||
| + | |||
| + | |||
| + | Control type setting is important to get the right control for the task.\\ | ||
| + | There are small differences for turntable or fiddle yard control.\\ | ||
| + | \\ | ||
| + | Control type 1 ,2 and 3 are made for turntables.\\ | ||
| + | \\ | ||
| + | Control type 4 is made for fiddle yard.\\ | ||
| + | \\ | ||
| + | |||
| + | ==== Control type 1: ==== | ||
| + | | ||
| + | turntable control , no shortest way possible.\\ | ||
| + | Turntable will never take shortest way.\\ | ||
| + | It will never pass zero.\\ | ||
| + | \\ | ||
| + | ==== Control type 2: ==== | ||
| + | |||
| + | Turntable will take shortest way, but this is restricted to a maximum of 3 times consistantly in one direction.\\ | ||
| + | It is very useful when cables are connected to the bridge.\\ | ||
| + | \\ | ||
| + | ==== Control type 3: ==== | ||
| + | |||
| + | Turntable will take shortest way, without any restriction.\\ | ||
| + | When the bridge is having contact rings for connection of power, there is no need to limit the turns in either direction.\\ | ||
| + | ==== Control type 4: ==== | ||
| + | |||
| + | Fiddle yard control.\\ | ||
| + | This is to control one lineair movement.\\ | ||
| + | The max limit switch is absolutely needed. \\ | ||
| + | Also it is important at first initialisation.\\ | ||
| + | Because all kind of settings have to be made, it can be harmful for your construction if motor runs out of its limits.\\ | ||
| + | This switch will at least stop the motor before that happens.\\ | ||
| + | |||
| + | ==== Motor voltage setting ==== | ||
| + | |||
| + | Setting correct motor voltage.\\ | ||
| + | Any voltage output from 5 to 24V is possible with GCA145 board. \\ | ||
| + | MGV145 board is limited to 18 V max.\\ | ||
| + | To be able to adapt to the required voltage, the used transformer should also be able to give the correct voltage and current.\\ | ||
| + | Here are some demands for the used transformer:\\ | ||
| + | |||
| + | ^ Output ^ Transfomer ^ | ||
| + | | 5 V | 9V mimimal | | ||
| + | | 12 V | 14 V mimimal | | ||
| + | | 18 V | 20 V minimal | | ||
| + | | 24 V | 24V minimal | | ||
| + | \\ | ||
| + | It is , by all means, allowed to use DC Power supplies.\\ | ||
| + | But please remind different minimal limits:\\ | ||
| + | ^ Output ^ DC Power supply ^ | ||
| + | | 5 V | 10 Volt minimal | | ||
| + | | 12 V | 16 Volt minimal | | ||
| + | | 18 V | 24 Volt minimal | | ||
| + | | 24 V | 30 Volt minimal | | ||
| + | \\ | ||
| + | For max power options, a transformer of minimum 50 VA will be sufficient in all cases.\\ | ||
| + | P1 is able to adjust output voltage for the stepper-motor.\\ | ||
| + | This voltage can be measured like on this picture.:\\ | ||
| + | | {{:gca:gca145_voltadjust.jpg?500}} | 10% higher than needed is no problem. | | ||
| + | \\ | ||
| + | ==== Motor current adjustment ==== | ||
| + | |||
| + | Thes settings are only possible with GCA145 board.\\ | ||
| + | === Currrent stepmotor unknown: === | ||
| + | |||
| + | The setting should be done in an experimental way.\\ | ||
| + | Simply turn P2 clockwise until you can hear soft clicking inside the trimmer.\\ | ||
| + | It is now set to maximum current.\\ | ||
| + | Now, slowly during the times that motor is running, turn the trimmer counterclockwise 1 turn at the time. \\ | ||
| + | Once found that the stepmotor suddenly does not have enough power left to move, you have gone too far.\\ | ||
| + | Turn trimmer a few turns clockwise and that is the approximate setting.\\ | ||
| + | |||
| + | === Currrent stepmotor known: === | ||
| + | |||
| + | If the output current of the motor is known, it can be adjusted .\\ | ||
| + | It is done by setting the right voltage on pin 15 of U2, according to this formula :\\ | ||
| + | V (U2 pin15) = I(stepmotor) / 2\\ | ||
| + | So if motor needs 0,5 A, this voltage should be 0,25V.\\ | ||
hardware_manual_gca145_version_7-3.txt · Last modified: 2018/11/12 08:56 (external edit)
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