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Copyright 2012 Gregory Bartlett
11/10/2014

Helix Light Controller

Helix V3 Main Board

Assembly and Setup Manual

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Summary of Contents for V3

Page 1: ...Copyright 2012 Gregory Bartlett 11 10 2014 Helix Light Controller Helix V3 Main Board Assembly and Setup Manual ...

Page 2: ... Resistors and Bypass Caps Steps 46 61 11 Pictorial Assembly 5 of 7 IC Sockets Switch and MOSFET Steps 62 73 12 Pictorial Assembly 6 of 7 Headers MP3 Sockets and Fuse Clips Steps 74 86 13 Pictorial Assembly 7 of 7 Remaining Components Steps 87 110 14 Assembly Notes 15 Assembly Pictures 17 Initial Power Up of the Main Board 18 Assembly of the MP3 Board 19 Final Assembly of the Main Board 20 Final A...

Page 3: ... controllers The second configuration is the Helix Network Node All Helix Main Boards that are not the Helix Network Controller are Helix Network Nodes The Network Node doesn t have the Real Time Clock RTC or the MP3 player In the assembly notes the parts that are not needed in a Network Node are identified The assembly and setup will follow these steps 1 Initial assembly of the main board 2 Initi...

Page 4: ...19 P8X32A D40 1 IC9 MCP23016 Mouser 579 MCP23016 I SP 1 IC10 ST485 Provided with the PCB J1 J2 J3 J4 J5 J6 RJ45 Mouser 571 5556416 1 6 MP3 MP3 Breakout Board SparkFun BOB 09943 1 MP3 not needed on HNN NE1 NE 2 Neon Lamp Mouser 606 A9A 1 Q1 TN0702N3 G Mouser 689 TN0702N3 G 1 Q1 not needed on HNN R1 R2 R3 R4 R5 R6 R7 220 ohm Resistor Mouser 291 220 RC 7 R8 100 ohm Resistor Mouser 291 100 RC 1 R9 R10...

Page 5: ...d on HNN U1 U2 TO 220 Heatsink Mouser 532 579302B00 2 Recommended Spacers Mouser 561 KSP117 4 USB to RS485 Option If you plan to use the board in a wired configuration only then you will need one set of the following parts Part Description Supplier Part Qty Notes RS1 USB to RS485 SparkFun BOB 09822 1 Not needed on HNN USB miniB Cable SparkFun CAB 00598 1 Not needed on HNN J7 RJ45 Mouser 571 555641...

Page 6: ...ed Brn 5 R4 220 Red Red Brn 6 R5 220 Red Red Brn 7 R6 220 Red Red Brn 8 R7 220 Red Red Brn 9 R8 100 Brn Blk Brn 10 R9 510 Grn Brn Brn 11 R10 510 Grn Brn Brn 12 R11 1 K Brn Blk Red 13 R12 1 K Brn Blk Red 14 R13 3 9 K Orn Wht Red 15 R14 10 K Brn Blk Orn 16 R15 10 K Brn Blk Orn 17 R16 10 K Brn Blk Orn 18 R17 10 K Brn Blk Orn 19 R18 10 K Brn Blk Orn 20 R19 10 K Brn Blk Orn Not needed on Network Node 2...

Page 7: ...n Network Node 63 IC2 Socket 8p DIP Socket See Note 8 64 IC10 Socket 8p DIP Socket See Note 8 65 IC3 Socket 6p DIP Socket See Note 8 66 IC4 Socket 16p DIP Socket See Note 8 67 IC5 Socket 16p DIP Socket See Note 8 68 IC6 Socket 16p DIP Socket See Note 8 69 IC7 Socket 16p DIP Socket See Note 8 70 IC8 Socket 40p DIP Socket See Note 8 71 IC9 Socket 28p DIP Socket See Note 8 72 SW1 Tactile Switch 73 Q1...

Page 8: ...Terminal Block See Note 14 Not needed on Network Node 94 TB8 2p Terminal Block See Note 14 Not needed on Network Node 95 TB9 2p Terminal Block See Note 14 Not needed on Network Node 96 C14 100 F See Note 15 97 C15 100 F See Note 15 98 J1 RJ45 Jack Cat 5 Jack 99 J2 RJ45 Jack Cat 5 Jack 100 J3 RJ45 Jack Cat 5 Jack 101 J4 RJ45 Jack Cat 5 Jack 102 J5 RJ45 Jack Cat 5 Jack 103 J6 RJ45 Jack Cat 5 Jack 10...

Page 9: ... and Resistors Steps 1 13 11 R10 10 R9 510 510 Grn Brn Brn Grn Brn Brn 7 R6 9 R8 220 100 Red Red Brn Brn Blk Brn 1 XTAL1 8 R7 32 768 KHz 220 See Note 1 Red Red Brn 4 R3 13 R12 220 1 K Red Red Brn Brn Blk Red 6 R5 5 R4 220 220 Red Red Brn Red Red Brn 3 R2 220 Red Red Brn 2 R1 220 Red Red Brn 12 R11 1 K Brn Blk Red These parts are not needed on a Network Node Main Board ...

Page 10: ...rn Blk Orn See Note 2 Brn Blk Orn 14 R13 3 9 K Orn Wht Red 20 R19 10 K Brn Blk Orn 25 D3 17 R16 1N5817 10 K See Note 2 Brn Blk Orn 30 RF1 L Socket 18 R17 10p SIP 2mm Pitch 10 K See Note 5 Brn Blk Orn 31 RF2 R Socket 15 R14 10p SIP 2mm Pitch 10 K See Note 5 Brn Blk Orn 28 XTAL2 5 MHz See Note 3 24 D2 1N5817 See Note 2 16 R15 10 K 23 D1 Brn Blk Orn 1N5817 See Note 2 29 U3 22 R21 DB101 100 K See Note...

Page 11: ...llow LED Green LED See Note 6 See Note 6 See Note 6 39 D16 Green LED See Note 6 44 D11 40 D17 Yellow LED Green LED See Note 6 See Note 6 37 D12 41 D18 Green LED Green LED See Note 6 See Note 6 36 D7 42 D19 Green LED Green LED See Note 6 See Note 6 43 D9 Yellow LED See Note 6 33 D8 Red LED See Note 6 34 D10 Red LED See Note 6 32 D6 Red LED See Note 6 These parts are not needed on a Network Node Mai...

Page 12: ... Resistors and Bypass Caps Steps 46 61 46 RA1 47 RA2 48 RA3 59 C10 10 K SIP Res 1 K SIP Res 220 SIP Res 0 1 F See Note 7 See Note 7 See Note 7 51 C2 61 C12 0 1 F 33 pF 58 C9 0 1 F 50 C1 52 C3 0 1 F 0 1 F 53 C4 0 1 F 57 C8 0 1 F 54 C5 0 1 F 49 RA4 55 C6 47 K SIP Res 0 1 F See Note 7 56 C7 60 C11 0 1 F 0 1 F These parts are not needed on a Network Node Main Board ...

Page 13: ...62 73 73 Q1 MOSFET See Note 9 64 IC10 Socket 71 IC 9 Socket 8p See Note 8 28p See Note 8 62 IC1 Socket 72 SW1 8p See Note 8 Tactile Switch 66 IC4 Socket 63 IC2 Socket 16p See Note 8 8p See Note 8 67 IC5 Socket 16p See Note 8 70 IC8 Socket 40p See Note 8 68 IC6 Socket 16p See Note 8 69 IC7 Socket 16p See Note 8 65 IC3 Socket 6p See Note 8 These parts are not needed on a Network Node Main Board ...

Page 14: ... 1 2p Header 0 1 See Note 10 See Note 10 See Note 10 78 H5 3p Header 0 1 See Note 11 79 H6 2p Header 0 1 See Note 11 76 H3 77 H4 3p Header 0 1 3p Header 0 1 See Note 10 See Note 10 75 H2 4p Header 0 1 See Note 10 83 MP3 L Socket 10p SIP 0 1 Pitch See Note 12 84 MP3 R Socket 10p SIP 0 1 Pitch See Note 12 85 F1A 74 H1 86 F1B Fuse Clip 4p Header 0 1 Fuse Clip See Note 13 See Note 10 See Note 13 These...

Page 15: ...te 14 108 B1 Socket 102 J5 Coin Cell Socket RJ45 Jack 98 J1 103 J6 RJ45 Jack RJ45 Jack 99 J2 RJ45 Jack 100 J3 RJ 45 Jack 96 C14 101 J4 100 F RJ45 Jack See Note 15 104 AJ1 97 C15 Stereo Audio Jack 100 F See Note 15 109 C13 4700 F 107 U2 See Note 15 3 3V Regulator See Note 16 105 NE1 Neon Bulb 110 T1 106 U1 87 TB1 3FD 412 5V Regulator 2p 0 2 Pitch See Note 17 See Note 16 These parts are not needed o...

Page 16: ...ition as necessary If the socket is not perpendicular then the XBee Radio will not plug into them properly After verifying that the socket is installed correctly solder all of the other pins See Picture 4 for an example of correctly installed RF1 sockets 6 Orientation matters with LEDs The LED has one pin longer than the other this is the anode The LED needs to be inserted in the PCB with the anod...

Page 17: ... tab on the side of one into the socket on the side of the next one Insert all eight terminal blocks into the PCB and solder from the bottom 15 This is an electrolytic capacitor orientation matters One side of the capacitor is marked as negative The pin on this side needs to be inserted in the round pad Make sure the capacitor is flush with the PCB 16 This is a TO 220 package voltage regulator ori...

Page 18: ...or Concerns contact the developer at Greg helixlightcontroller com Assembly Pictures Square Pad Light Band Picture 1 Picture 2 RTC Crystal Diodes XBee Sockets Picture 3 Picture 4 Propeller Crystal XBee Sockets MP3 Sockets Picture 5 4 Pin Header Picture 6 MP3 Sockets ...

Page 19: ...face 5 Plug in the power cord 6 The Power LED D6 should be illuminated if not then unplug the power cord and troubleshoot the power supply section of the board The Power LED is powered by the 3 3VDC regulator which in turn is powered by the 5VDC regulator which is connected to the transformer via the full wave rectifier and filter capacitors 7 With the main board plugged in carefully touch the hea...

Page 20: ...ts of 10 pads Do not install headers in third set Carefully break off two 10 pin headers off of the 40 pin 0 1 pitch strip header Mouser Part 517 6111TG Insert the shorter pins of one of the 10 pin header through the bottom side of the break out board Solder one of the pins in place on the top of the break out board Make sure the header is flush with the bottom of the board and perpendicular to th...

Page 21: ...Notch Up 9 IC9 MCP23016 I O Port Expander Notch to the Right 10 IC10 ST485 RS485 TX RX Port Notch Up 13 RF1 XBee Pro Radio Outline of the radio should match the outline on the silkscreen 14 MP3 MP3 Player If this is a Network Node MB then skip this step Align Vin and GND markings on the MP3 player with Vin and GND markings on the silkscreen See Picture 10 15 Heat Sink for 5V Regulator Apply a litt...

Page 22: ...nfiguration File 10 kB Helix Show File 10 kB Helix Playlist File 10 kB Helix Schedule 10 kB MP3 File 1 MB Minute Helix Sequence File at max channel cnt 1 568 ch 1 8 MB Minute at 50 mS event period Therefore for a 20 minute show the total memory required is approximately 72 kB 20 1 MB 20 1 8MB 56 MB Even if there are two hours of MP3s for the Playlist the total size would only be 176 MB So any Micr...

Page 23: ...RAT MP3 CALIBRAT SEQ For testing download the file at http www helixlightcontroller com downloads SetupTest zip Unzip the file to your hard drive If you are testing a Helix Network Controller then copy the contents of the Helix 1 directory to the microSD card If you are testing a Helix Network Node then copy the contents of the Helix 2 directory to the microSD card If you are testing more than one...

Page 24: ...l 32 channels of lights connected to the Main Board then they should flash on sequentially for about one second each If you only have four channels of lights connected then Channels 1 4 should flash on sequentially for about 1 second each After the Channel 4 light goes out it will take about 28 seconds before Channel 1 will start to flash again You should move the single SSR to each of the Channel...

Page 25: ...ld flash on and off several times 4 The Heartbeat LED should start flashing on and off about every second 5 About 20 seconds later the MP3 player should start playing a 5 minute song and the lights should flash in sequence to the song The song should repeat over and over until the Main Board is unplugged Don t worry if the lights don t flash in exact synchronization with the song at this time You ...

Page 26: ...ow File Name Monday Start Time midnight Tuesday Start Time midnight Wednesday Start Time midnight Thursday Start Time midnight Friday Start Time midnight Saturday Start Time midnight Listing 1 Original SCHEDULE SCH 1 1 0000 2359 S SETUPT 1 SHW 2 1 0000 2359 S SETUPT 1 SHW 3 1 0000 2359 S SETUPT 1 SHW 4 1 0000 2359 S SETUPT 1 SHW 5 1 0000 2359 S SETUPT 1 SHW 6 1 0000 2359 S SETUPT 1 SHW 7 1 0000 23...

Page 27: ...ime 11 59 PM The next line S signifies that the entry is a show If it was a playlist then it would have been a P The last line in the series 120BEA 1 SHW is the file name of the show to play The reason that the Helix starts playing the song immediately after boot up is the start time is midnight and the stop time is 11 59 PM The system must be idle in order to set the time and calibrate it The sta...

Page 28: ...urrent day to about 30 minutes from the current time Save the file back to the MicroSD card and insert it back into the Helix Network Controller Board 1 Connect an XBee Pro Radio to your PC using the XBee USB Carrier Board and USB cable 2 Start the Helix Network Supervisor application There should be a shortcut in the Start menu 3 Select the COM Port that the XBee Pro Radio is connected to from th...

Page 29: ...operly configured but hasn t joined a Helix Network yet At this point the Helix Network Node is properly configured and ready to join a Helix Network 1 Edit the SCHEDULE SCH file on the Helix Network Controller MicroSD card to have the show start immediately The easiest way to do this is to set the start time to 0000 and the end time to 2359 Save the SCHEDULE SCH file back to the MicroSD card 2 In...

Page 30: ...oard can then be mounted to it using 6 x 1 pan head sheet metal screws and nylon spacers such as Mouser Part 561 KSP117 When mounting the Main Board to the back panel be sure it is positioned with plenty of room at the top of the board for easy access to the MicroSD card and Audio Jack It is recommended that the power cord be secured to the back panel using tie wraps and tie wrap mounts See Pictur...

Page 31: ... s DMX SSRs will operate using standard Cat5 patch cords The Renard series of controllers require a cable with the pin out shown in Figure 1 8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1 Helix Channel Bank Renard Input Figure 1 Helix to Renard Pin out LOR controllers require a cable with the pin out shown in Figure 2 8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1 Helix Channel Bank LOR Input Figure 2 Helix to LOR Pin out DMX ...

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