MiniRen32/8 Chamelen Assembly & User Guide Overview Chamelen is a 32 channel Renard cntrller that has 8 triac utputs, an n-bard pwer supply and is capable f using either the Renard r DMX prtcl at speeds up t 460kbps when used with standard Renard-Plus firmware fr the PIC18F4520 chip. Chamelen utilizes the DIGWDF SISO r wireless Snap-In adapters fr cnnectin t the utside wrld, which pens up the capability t use the Kmby r Renard-Plus nrf-based adapters as well. Alternately, an USB-TTL adapter can be used as multiple cmmunicatin headers are designed int the circuitry. The bard cncept allws selecting any eight f the 32 available cntrl channels fr cntrlling the eight Triac utputs. As the bard is prduced using 2z cpper traces and the Triac pwer sectin is duplicated n the tp and bttm f the PCB, Chamelen can accmmdate up t 10A ttal current ver its eight Triac pwer circuits. BOM Bill f Materials Quantity (*=ptinal) Part# Descriptin Surce 1 579-PIC18F4520-I/P PIC18F4520 taydaelectrnics.cm 1 A-292 40-pin DIP scket taydaelectrnics.cm 2 A-2076 750-hm 1/4w resistr 5% taydaelectrnics.cm 9 A-2075 680-hm 1/4w resistr 5% taydaelectrnics.cm 8 A-2061 180-hm 1/4w resistr 5% taydaelectrnics.cm 1 A-2102 27K-hm 1/4w resistr 5% taydaelectrnics.cm 1 A-179 5v, 1A vltage regulatr taydaelectrnics.cm 1 782-H11AA1 H11AA1 ptcupler muser.cm 1 625-DF01M-E3 Bridge rectifier, 1A, 100v muser.cm 1 838-3FS-312 Transfrmer, 12.6v/6.3v 200/400ma muser.cm 2 A-5015 Fuse hlder, 5x20 mm taydaelectrnics.cm 1 A-357 Fast-acting 10A 5x20mm fuse taydaelectrnics.cm 9* A-624 6-pin DIP scket taydaelectrnics.cm 8 A-189 BTA06 Triac, 6A, 600v taydaelectrnics.cm 9 A-664 5mm terminal blcks taydaelectrnics.cm 1 A-4526 2200uf 16v electrlytic capacitr taydaelectrnics.cm 4 A-214.1uf nn-plarized capacitr taydaelectrnics.cm 1 A-261 Standard LED taydaelectrnics.cm 8 A-909 MOC3023 ptcupler taydaelectrnics.cm 2 A-197 40-pin breakaway header strip taydaelectrnics.cm 1 A-2374 Jumper wires, 200mm, F-F, pack f 40 taydaelectrnics.cm 1 PCB MiniRen32/8 Circuit Bard DIGWDF Stre 1* SISO MiniRen SISO Adapter DIGWDF Stre 1* Snap-In XBee Snap-In Adapter DIGWDF Stre Part Substitutins The resistrs, capacitrs, 5mm terminal blcks, Triacs, header pins, fuse/fuse hlders, DIP sckets and ptcuplers are cmmn parts and can easily be substituted with similar values as lng as they will fit in the spaces allcated fr them n the PCB. The PIC18F4620 can als be used in place f the lesser expensive PIC18F4520. DIGWDF MiniRen32/8 Chamelen - Assembly & User Guide Page 1
Assembly Like all DIGWDF prducts, we recmmend building the bard by cmpnent height, installing the smallest/shrtest/thinnest cmpnents n the PCB first with the tallest cmpnents being installed last. Nte that the Chamelen s 2z cpper will require a bit mre heat r time t flw the slder, s use a nice, ht irn and be patient when sldering the cmpnents t the bard. Install and slder the 20 resistrs in their respective lcatins. The resistr values are printed n the PCB s silkscreen. When dne, be sure t clsely clip the excess leads frm the bttm f the bard. Install and slder the DF01 vltage rectifier, matching the markings n the chip t the markings n the PCB and ignring the chip s ntch lcatin if it cnflicts with what is printed n the PCB. Install and slder the 6-pin DIP sckets fr the H11AA1 chip and eight MOC3023 chips. Be sure t rient the scket t match the marking n the PCB t eliminate any cnfusin later when it cmes time t insert the chips in the sckets. NOTE: DIP sckets are ptinal; if yu prefer t slder chips directly t the bard, that s perfectly acceptable. Install and slder the 40-pin DIP scket, rienting the ntch tward the edge side f the PCB. The scket is highly suggested in place f sldering the 18F4620 chip directly t the PCB. Install and slder the LED in its respective lcatin, making sure t rient the LED matching the flat side f the LED t the flat utline n the PCB. Break ff tw, 20-pin rws f header pins. Then hld ne f the rws next t the edge f the PIC lcatin that displays channels 1-16 alng the side. There shuld be a pin fr each hle. Using pliers, remve the tw pins frm the rw that match the tw hles marked C5. Yu shuld end up with a rw with 8 pins n ne side, a 2-pin gap near the middle, and 10 pins n the ther side, like this ne. Install and slder it in with the pins pinting upward frm the tp f the bard. Be sure NOT t apply slder where the pins have been remved. With the secnd rw f 20-pins, hld the rw against the side f the PIC lcatin marked 17-32. There shuld be a pin fr each hle. Using pliers, remve the tw pins frm the rw that match the tw hles marked C4. Yu shuld end up with a rw with 10 pins n ne side and 8 pins n the ther with a 2-pin gap near the middle, like this ne. Install and slder it in with the pins pinting upward frm the tp f the bard s that the gap matches the lcatin marked C4. Be sure NOT t apply slder where the pins have been remved. Break ff tw, 6-pin rws f header pins. Install and slder them at the lcatins marked SISO and ICSP. Break ff ne, 5-pin rw f header pins. Install and slder it at the lcatin marked RenW Header. Break ff ne, 8-pin rw f header pins. Install it at the lcatin marked Output Channels. Install and slder tw.01 capacitrs at the lcatins marked n the PCB next t the L7805CV regulatr and t the right f the ICSP header. DIGWDF MiniRen32/8 Chamelen - Assembly & User Guide Page 2
Install tw mre.01 capacitrs at the C4 and C5 lcatins, carefully inserting the leads dwn thrugh the hles where the header pins were remved and sldering them n the bttm f the PCB. Cnnect a rw f 4 terminal blcks tgether (they link tgether fr strength). Install and slder it in place alngside the lng edge f the bard with the wire access penings facing the edge. Repeat with anther set f 4 terminal blcks fr the ther 4 utputs. Install and slder a terminal blck at the lcatin marked Pwer. Assembly tip: with single terminal blcks, it ften helps t carefully dab a bit f crazy glue nt the bttm f the terminal blck edges and then press it int place; hld until it sets usually nly a few secnds. Then slder the terminal blck in. The crazy glue helps prevent twisting when yu screw dwn cnnectins n single terminal blcks. Install and slder the fuse hlder. Install the fuse and cver, t. Install and slder the eight Triacs in their lcatins, being careful t rient them s that the metal tabs are tward the terminal blcks. It helps t slder nly ne leg f a Triac at a time, which gives yu a chance t straighten and align them befre sldering the ther legs. Be sure t clip ff the excess leads frm the bttm f the PCB afterward. Nte: because the cpper traces are duplicated n bth the tp and bttm f the PCB, sldering the Triacs will take a little mre heat than nrmal t flw the slder. Be patient! Install and slder the L7805CV vltage regulatr, being sure t rient the metal tab tward the resistrs and away frm the.1uf capacitr. Clip ff the excess leads afterward. Install and slder the 2200uf electrlytic capacitr with the negative stripe n the capacitr tward the edge f the bard (the + side ges int the square hle n the PCB). Install and slder the transfrmer in place, being sure t munt it with the 4-pin side tward the edge f the PCB. Clip the excess leads afterward. This cmpletes the basic assembly f the MiniRen32/8 Chamelen. Initial Testing CAUTION 120VAC VOLTAGE IS PRESENT! Yu will need yur DVM r VOM fr testing. Cnnect a pwer cde t the POWER terminal blck, making sure that the HOT side f the plug is tward the 120v side and the neutral plug is tward the Neut side f the terminal blck. When the bard is pwered up, be very careful nt t tuch any f the circuits with anything ther than yur DVM prbes and dn t pick up the bard at all because 120vac is present! Plug the bard int 120vac pwer. The pwer LED shuld light. If it des nt light, immediately unplug the bard. Check t make sure a gd fuse is installed and that all slder jints are shiny, smth and cmplete. If nt, reflw slder jints as necessary. If the pwer LED lights, cntinue with preliminary vltage testing. Cnnect the grund lead f yur DVM t the metal tab n the L7805CV regulatr. This is a cmmn grund psitin. Set the DVM set t 20 vlt DC range (r at least 15vdc). In these tests, stated vltages are apprximate and may vary slightly frm ne bard t the next. Use the + DVM prbe t test the fllwing: The + side f the DF01 rectifier chip shuld read apprximately 7.5 vdc. The +5v pin n the SISO header shuld read apprximately 4.9-5.1vdc. DIGWDF MiniRen32/8 Chamelen - Assembly & User Guide Page 3
The +5v pin n the RenW header shuld read 4.9-5.1vdc. Pin #2 f the ICSP header shuld read 4.9-5.1vdc. Pin #1 f each f the eight MOC3023 chip sckets shuld read 4.9-5.1vdc. Pin #10 and pin #32 f the PIC scket shuld read 4.9-5.1vdc. (Pin #10 is right after the bard marked 8. Pin #32 is just befre the bard marked 24.) If initial testing is kay, UNPLUG the bard frm 120vac pwer. Insert the H11AA1 chip in its scket, taking care t rient the ntch n the chip t match the PCB. Plug the bard int 120vac pwer again and test the H11AA1 s utput vltage: The ZC pin n the SISO header shuld read apprximately 5-8vdc. If the ZC test is kay, UNPLUG the bard frm 120vac pwer. Insert the MOC3023 chips in the sckets, taking care t rient the ntch n the chip prperly f if there is n ntch, the dt marking pin #1 n the chips shuld be n the sides f the sckets alngside the 680 hm resistrs. Take care t ensure that all six f each chip s pins are seated IN the sckets and nt bent r splayed utward. Install the PIC18F4520 chip. Nte: Yu may r may nt want t flash the chip with yur firmware first it desn t really matter since yu can reflash it later n by cnnecting yur PIC prgrammer t the ICSP header. PIC installatin tip: large, multi-pin chips can be tricky t install s dn t rush. Carefully align the pins first s they match the width f the scket and are straight. Yu may want t use a frceps r tweezers t slightly bend the pins s they ll g straight in. Lightly set the 18F4520 chip in place and verify that the pins will fit nicely befre yu prceed. When satisfied, using bth thumbs, apply light pressure n bth ends f the chip, gently rcking the chip ever s slightly frm end t end until it s seated firmly in the scket. While yu re inserting the chip, be aware f any pins that are bending and nt ging int the scket s yu can stp, reverse yur actins and remve the chip, fix the bent pins and start ver. Assembly is cmplete. Attach either a cmpleted SISO r Snap-In adapter t cmmunicate yur cntrl signals t the Chamelen and prvided the 18F4620 chip is flashed with the prper firmware, yu can test the cntrller in live peratin. REMINDER: Whenever the cntrller is plugged int 120VAC pwer, be extremely careful wrking with it because electrically ht circuits are expsed! DIGWDF MiniRen32/8 Chamelen - Assembly & User Guide Page 4
Cnfiguring the Chamelen Chamelen is a bit f an advanced cntrller cncept and it s expected that the persn that assembles ne already has an adequate grasp f setting firmware start addresses, baud rates cmpiling and flashing firmware and the like. The prcess f mdifying the firmware and flashing the PIC18F4520 with it is ably cvered elsewhere at bth the Renard-Plus web site (www.renardplus.cm) as well as in the diychristmas.rg frum s it wn t be addressed here in this guide. Hw t assign a PIC cntrl channel t a Triac utput This is simple. Let s assume yu want t cnnect PIC channel 6 t Triac utput #3. Simply cnnect a jumper wire frm the header pin marked 6 next t the PIC t the Output Channel marked with a 3. Dne. What s nt s clear is that in yur head and in yur sequence, yu have t keep track f what channel that is in yur sequence, what the Chamelen s pic channel #6 is ding and what lights it s cntrlling! We can t help yu there yu just have t think it thrugh. Writing it dwn is prbably a pretty gd idea. It s just simple mapping: the head bne s cnnected t the neck bne, and the neck bne s cnnected t the shulder bnes and just wrk it thrugh. Dn t ask the DIGWDF engineers t figure it ut fr yu they dn t even knw hw t cunt their wn fingers yet. Daisy Chain vs Bypass mechanisms fr data This is easier than it sunds and yu need t understand the Chamelen s architecture t use it effectively. It s perhaps easier if yu remember that Chamelen has multiple data in pins and data ut pins. There are DI (data in) pins n bth the SISO and RenW headers, marked RX fr receive. These pins are where data arrives at the bard frm yur cmputer r anther cntrller and they are cnnected tgether s if yu cnnect t ne f them, yu re cnnecting t bth f them. Likewise, there are DO (data ut) pins n the SISO header and n the RenW header, t. These pins are where data exits the bard t g t the next cntrller in line and bth DO pins are cnnected tgether, t. Lastly, there are DI and DO pins n the PIC but they re nt cnnected t anything yet. Essentially what yu d is cnnect the data surce t the pin where yu want that data t g. It s that simple -- just fllw the flw f data yu want t have. First f all, it may help t have a little review f the difference between the tw terms: Daisy Chain mde: the classic Renard mde is such that the cntrller eats data as it gets it and it desn t pass it alng. What this means is that the Renard cntrller eats/uses up the first X numbers f channels and nly passes the remaining channels ut the PIC s utput pin. If it s a 32-channel cntrller and there are 200 ttal channels f data, it eats the first 32 and passes channels 33-200 (the leftvers) n t the next cntrller thrugh its DO (data ut pin. The beauty f a daisy chain mde is that it s aut-addressing. The ugly part f the daisy chain mde is that t make it wrk best, all yur cntrllers need t have the same channel cunt which may nt be feasible fr everyne. After all, yu may have 8, 16, 24, 32, 48, 64 r 96 channel cntrllers in use in yur shw. Each ne f them eats as many channels as it is designed t use and if yu were t swap-ut a 16-channel fr an 8-channel, it cmpletely changes the channel usage f yur layut. DIGWDF MiniRen32/8 Chamelen - Assembly & User Guide Page 5
BYPASS mde: this happens when yu cnnect the input data directly t the utput that s suppsed t g t the next cntrller. Therefre, yu re nt even using the data utput frm the PIC s DO pin yu re bypassing it and feeding the input directly t the utput and the next cntrller in line gets exactly the same channel data that this cntrller received. S if 200 channels were received by cntrller #1, in bypass mde, cntrller #2 gets the same 200 channels sent t it, t. In a way, it s kind f like having a Y-splitter n the data cable with ne cable ging t ne cntrller and the ther cable ging t the next cntrller. This pens the dr fr using and addressing system s that yu can specific which X channels ut f the ttal channel pl yu want that cntrller t use and yu can cmpletely ignre the DO (data ut) frm the PIC because yu re nt ging t use it. DAISY CHAIN MODE SETUP Cnnect the DO f the PIC t the DO pin f either the SISO r RenW header, and cnnect it t the utput that yu re NOT using t cnnect t the next device. Example-1: assuming that yu re using the SISO adapter t cnnect t the next cntrller, cnnect the PIC s DO pin t the DO pin f the unused RenW header because the DO pins n ne is the same as the DO pin n the ther. Example-2: assuming yu re cnnecting wirelessly t the Chamelen thrugh the RenW header and a Snap-In, cnnect the Snap-In s +5 and G t thse same pins n the RenW header, cnnect the RX pin t the DI pin n the PIC, cnnect the DO pin n the PIC t the DO pin n the Snap-In, and cnnect the XMIT jumper n the Snap-In. BYPASS MODE SETUP Cnnect the DI f the PIC t the RX pin f either the SISO r RenW header (whichever adapter yu re using t push data t the Chamelen). Then cnnect the DI pin f the OTHER header t the DO pin f the same header. Example-3: if yu re sending data frm yur cmputer t the Chamelen thrugh the SISO adapter, then the RenW header is unused. Yu d cnnect the RX pin f the RenW header t the DO pin f the RenW header. The SISO bard s DO pin will then have the same data and will send the data ut t the next cntrller in line. (Nte: alternately, yu culd simply cnnect the RPTR jumper n the SISO itself and it wuld d the same thing then yu wuldn t need t cnnect anything t the RenW header at all!) Example-4: assuming yu re cnnecting t the Chamelen wirelessly and want t retransmit the signal back ut, cnnect the Snap-In t the +5v and G f the RenW header; cnnect the RX and DO pins n the Snap-In, and cnnect the XMIT jumper n the Snap-In. Als cnnect the RX pin f the SISO header t the DI pin f the PIC. (Nte: unless yu have an excellent grasp f the wireless issues related t wirelessly retransmitting data, dn t attempt this. If yu retransmit n the same frequency as the main transmitter, yu re asking fr truble as it will cause hrrible crsstalk issues n yur wireless netwrk when mre than ne transmitter is sending ut data. Fr wireless t wrk best, there shuld be nly ne transmitter n a channel/ssid fr each netwrk.) DIGWDF MiniRen32/8 Chamelen - Assembly & User Guide Page 6
Trubleshting Pssible issues and cures Vltages dn t match the guide Check sldering; reflw all jints n pwer circuit cmpnents and elsewhere that +5vd is fund. Make sure DVM/VOM has a gd battery. If battery is lw, they dn t measure accurately. LED desn t light Check yur sldering The LED may be installed backwards Check sldering f the 680 hm resistr near the L7805CV and the LED Chamelen is nt pwered n r the fuse is brken/blwn N respnse frm Chamelen when sending data t it Check jumper wire cnnectins t make sure yur incming data is ging t the DI pin f the PIC. Check t make sure yu re actually sending data t Chamelen put a scpe n the DI pin f either the SISO r the RenW header, r use the DirkCheapSST t check fr the stream f data. The address f the PIC may be utside the bunds f the data being sent. Fr example, if the PIC is set t start at channel 281 but yu re nly sending 280 r fewer channels f data, there s n data fr the PIC t get. The PIC s utput channel is nt cnnected t the right TRIAC utput channel. N pwer t Chamelen r the fuse is missing/blwn Sequence des nt have enugh active channels r sequence is nt sending data ut frm the cmputer. Brken r invalid cnnectin wiring t Chamelen. If wireless, the wireless netwrk settings may nt be crrect fr the PIC and/r the wireless adapter. This is a bigger issue than can be addressed here. MOC3023 is in the scket backwards r a pin is bent and nt cnnected. One r mre f the PIC s pins are bent/nt cnnected in the scket. Check the cntinuity f the jumper wires a cnnectr might be bad. Firmware is nt crrectly cmpiled and/r the PIC flashed prperly. Dimming is erratic Check the H11AA1 chip t make sure it s seated crrectly in the scket. Check sldering fr the H11AA1 scket, the 750 hm and 27K resistrs and the PIC at pin #1 Swap-ut the H11AA1 with a knwn-gd chip t see if the chip is defective. Firmware is cmpiled incrrectly and the PIC is nt reading the ZC signal. Put a scpe n PIC pin#1 t see the ZC signal, r use the DirkCheapSST instead. Pr incming data cnnectin. DIGWDF MiniRen32/8 Chamelen - Assembly & User Guide Page 7
Channel Assignments t Header Pins When the first run f PCBs was prduced, the bard s silk screen was, unfrtunately, incrrect. Pins 1-16 are crrectly displayed n the PCB but channels 17-32 are nt. Belw is the CORRECT rientatin f all channel assignments t header pins: DIGWDF MiniRen32/8 Chamelen - Assembly & User Guide Page 8