HCS_C Connection Users Manual

First revision 11/25/2006

Author: Robert D. Morrison
NOTE: This file and contents are protected by copyright
Robert D. Morrison Copyright July 2005 All rights reserved.

Updated 8/15/2005: added current limit adapter

Updated 2/10/2008:  Added Insteon cable assembly instructions

Updated  2/23/2008:  Added HCS_C Missing Resistor fix

2/23/2008 MISSING RESISTOR FIX!  

There's a missing resistor that pulls down the daughtercard wait input if there is no daughtercard.  The potential for a problem has always been there, but the new version 1.08 bits seems to be more susceptible to hangs because of the wait signal being a floating input without the resistor.  I will soon put up more detailed pictures on how to add the resistor will appear in a few days, but for now this should help:  The 20k resistor can be surface mount or radial, 1/8 or 1/16 watt is fine.  The large metal plane on the back is ground, you can tie the resistor to the pin 16 and ground easily on the back side (dont ruin the daughtercard connector, of course--you'll want it in good shape for the forthcoming ethernet card!)

This document may not be used in whole or part except by express written consent of the author. Commercial use of this code is prohibited. The author may not be held liable in any way for any consequences or misuse of this file or any portion thereof.

POWER CONNECTOR

HCS_C Power Connector for HCS_C MAIN BOARD or for the HCS_C Combo Card.  The HCS_C main board draws around 400mA, the HCS_C Combo Card about 100mA (no loads driven).

This heavy duty three pin connector, located left of the HCS_C main board just below the 10 pin emulation JTAG connector and the reset button, accepts any voltage from 9V to 5V.  It is regulated down to 3.3V.  The outside pins are ground and the middle pin is the power supply input.  NOTE:  You can put the connector in either way, back or front--but BE SURE IT IS CENTERED!!  If you accidentally dont get the connector on all three pins, you may apply reverse voltage and FRY YOUR HCS_C!!  Never hook up power when you are tired, frustrated, or distracted--this is where most people make fatal mistakes!!  A current limited power supply is available, see below, this has saved my rear more times than I can count--highly recommended.

HCS_C COMBO CARD PINOUTS  (NOTE: THIS BOARD IS MOSTLY 3 VOLT--ONLY THE ANALOG SIGNALS ARE 5V TOLERANT!!)

CURRENT LIMITED POWER SUPPLY

I highly recommend a current limited supply (about 700mA) which will limit damage if you short, reverse connect, or accidentally apply excessive voltage to your HCS_C.  It's really great insurance--we all make mistakes at times, so spending a little extra money to limit power supply damage is a really smart idea.

Here's the circuit--it seems to work well, but send me email if you see improvements:

Here's a photo:

HCS_C IO PINOUT

There are 32 inputs and 32 outputs on HCS_C.  They are buffered and have optional IO protection consisting of 100ohm resistors, 100pF capacitors, and diodes to +3.3 and ground.  The buffers are 5V tolerant.   NOTE:  THE "V" pins are 3.3V!! DO NOT HOOK UP 5V TO THESE PINS!!  These pins can supply power to external circuitry, but must be limited to about 2A total.  IF YOU USE EXTERNAL CIRCUITRY YOU MUST USE A SUBSTANTIAL HEATSINK ON THE 3.3V REGULATOR (right next to the HCS_C power connector).

INSTEON CONNECT TO THE HCS_C AUX RS232 CONNECTOR:

Use the Smartlabs Power Line Modem, #2412S (NOT the PLC).  You will need to take the modem cable (it's just a CAT5 ethernet cable) and cut it in half, then wire for the 8 pin RS232 connector on the upper right hand corner of the HCS_C.  Check carefully, the PLM has +12V that could fry your HCS_C.  I would double check your wiring against the Insteon PLM specifications--I tried to be careful here but I could have made a mistake somewhere.  The Green wire shown is ground (pin 7 on the RS232 connector to the 2412S), the Purple wire pin 8 on the Insteon PLM RS232 connector is the RX input to the PLM (this is output from HCS_C), and the Blue wire pin 1 of the RS232 connector is the TX output from the PLM.  Do not make any other connections to the RS232 connector on the HCS_ main board.

POWER CONNECTIONS TO THE IO CONNECTORS


You can safely make connections from 5V devices directly (ONLY ON THE HCS_C MAIN BOARD.  The HCS_C COMBO BOARD WILL NOT ACCEPT 5V INPUTS), the buffers on HCS_C are +5V tolerant inputs, and will drive outputs rail-to-rail at 3.3V.  I'd tie just one output/input, and operate that way for a little while. But that's just me being paranoid. There is no specified reason why this should not be perfectly safe.

The IO connectors have several ground and power pins (3.3V, don't tie them to +5V! That's why I recommend that you make your HCS_C system all 3.3V--as much as I work with HCS_C, the chance of making a fatal mistake applying +5V to the +3.3V was too high--so be very careful if you have a mixed voltage setup). Note that the IOs are not intended for highspeed/high drive signal operation, there is no crosstalk protection between signals on this bus. If you end up with crosstalk, try using a shielded 40 pin shielded cables, I think that should fix that if it shows up.  Note that I previously recommended an IDE shielded cable, but it occurred to me that there are preset grounds on those cable pins, so they won't work.

The Voice input can be connecteddirectly to the line out (about 1V P-P or so) of your computer or other audio device.  The Voice audio output  is also line output compatible (1V P-P).  Please start with a low volume setting for the line in or out to prevent unexpectedly high voltages.  Check your audio configuration by issuing a VOICE(0) = ON (playback sound at address 0, or any 11 bit address).  Each address location holds about 1 millisec of sound, you can choose to start anywhere.  If there is recorded data there, it will play until it detects that the recording data for that message has stopped.  You should hear the initial message (“Your HCS_C Combo Card is working fine” or something like that).  Be careful issuing record commands (VOICE(0) = RECORD) since it will wipe out whatever messages are already there.  You must issue a record unlock command HCS_FPGA(0) = 4 (bits 0-2 set to 0x4) to record.  To record, issue the VOICE(XXX) = RECORD command sequence, where XXX is the starting address of the recording.  Stop the recording with a VOICE(0) = OFF command.  See the WinBond ISD4004 data sheet for more information on programming the Voice recorder, although those three commands really are the only ones you’ll need.

HCS_C MAIN BOARD SERIAL CONNECTIONS

Front Top View of Right Hand side of the HCS_C Main Board

Quick-Start Guide for the HCS_C Combon Card

Revision 1.0 Robert Morrison 1/1/2007

Unpack your HCS_C Combo card carefully in a static free environment.  Note the scotch tape that wraps the whole package is a great static electricity generator, keep it away from the anti-static bag contents.

The zetaengineering website has connection details.  Here is a useful summary.  Power to the board must be 5 volts, this is regulated down to 3.3V, although all of the analog circuitry runs at 5V.  Use special caution with this dual voltage setup.  You will fry this board if 5V somehow gets on to the 3V supply.  The top-side plane is 3.3V, the bottom plane is ground. 

Before connecting your HCS_C Combo card to the HCS_C Main board, find a LCD monitor (I do not recommend a CRT, but in any case be absolutely sure your monitor does not have a live ground).  Connect the LCD monitor to the video connector and apply 5V (the three pin power connector has pinout GND, +5V, GND, so it is symmetric, it doesn’t matter which way—but be very careful to center the connector otherwise you will apply reverse voltage).  You should see a powerup screen.  If you don’t, or something smells or feels hot, shut down immediately, something is wrong.

Please NOTE:  the DAC inputs and ADC outputs are not wired directly to the terminal posts, but to connector holes adjacent to the prototyping area.  Since the analog outputs almost always require some type of front end circuitry, you will need to make the appropriate connections to the terminal ports.  These analog signals are buffered and filtered with single stage Butterworth filters, but don’t allow signals less than zero or above +5V.  Also note.  The terminal block has +3.3V, NOT 5V.  Don’t connect +5V to the 3.3V!!  Please be very careful with power connections, the risk of mistakes is very high.

The Voice input can be connected directly to the line out (about 1V P-P or so) of your computer or other audio device.  The Voice audio output  is also line output compatible (1V P-P).  Please start with a low volume setting for the line in or out to prevent unexpectedly high voltages.  You must precede every Voice command value with a powerup command (CMB1 V=x2000).  Check your audio configuration by issuing a CMB1 V=xE000 (playback sound at address 0, or any 11 bit address).  Each address location holds about 1 millisec of sound, you can choose to start anywhere.  If there is recorded data there, it will play until it detects that the recording data for that message has stopped.  You should hear the initial message (“Your HCS_C Combo Card is working fine” or something like that).  Be careful issuing record commands (CMB1 V=xA000) since it will wipe out whatever messages are already there.  You must issue a record unlock command (HCS_FPGA(0)  bits 0-2 set to 0x4) to record.  To record, issue the 0x2000, 0xAXXX command sequence, where XXX is the starting address of the recording.  Stop the recording with a 0x2000 command.  See the WinBond ISD4004 data sheet for more information on programming the Voice recorder, although those three commands really are the only ones you’ll need.

You should be able to plug in any PS2 compatible computer keyboard into the keyboard connector.  However, you must then supply power to the little three pin connector on the video adapter, it is also GND, +5V, GND.

The 16 IO lines powerup in the input state with weak pullups.  To select any bits for output, issue a CMB1 D=xFFFF command (to turn all bits to outputs).  Then use the CMB1 I=x<value> command to set or reset the outputs.  The relays should powerup in the off state.   This is true also for the 16 channel relay boards that are attached to the IO port,  the weak pullups are not enough to turn them on.  Just don’t forget the D command before trying to switch the relays.

One last thing—the LCD connector will directly drive a SEEtron type TTL compatible LCD display.

Enjoy!  Send questions to zeta@zetaengineering.com