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hardware_manual_gca145_version_7-3 [2018/11/12 08:56] (current)
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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)