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WIRING_ESP32-2432S028R.md
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WIRING_ESP32-2432S028R.md
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# ESP32-2432S028R Wiring Guide
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## Overview
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This document describes the external connections needed for the DCC-Bench project using the ESP32-2432S028R module.
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## Built-in Components (No Wiring Needed)
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The ESP32-2432S028R module includes:
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- ✅ ILI9341 TFT Display (320x240)
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- ✅ XPT2046 Touch Controller
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- ✅ MicroSD Card Slot
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- ✅ USB-C Power/Programming
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## External Connections Required
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### 1. LM18200 H-Bridge Driver (Universal DC/DCC Output)
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The LM18200 serves as **BOTH** the DC motor controller AND DCC signal booster.
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It's the same hardware - the ESP32 just sends different signals depending on mode:
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- **DC Mode**: ESP32 sends PWM + direction signals
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- **DCC Mode**: ESP32 sends DCC digital signals
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```
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ESP32 GPIO 18 (PWM/DCC_A) ──→ LM18200 PWM Input
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ESP32 GPIO 19 (DIR/DCC_B) ──→ LM18200 Direction Input
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ESP32 GPIO 23 (BRAKE) ──→ LM18200 Brake Input
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ESP32 GND ──→ LM18200 GND
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ESP32 5V ──→ LM18200 Logic VCC
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Power Supply (12-18V) ──→ LM18200 Motor Power
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```
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**LM18200 Outputs (to Track):**
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```
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0.1Ω 1W Current Sense
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LM18200 OUT1 ──→ ───┬──────╱╲╲╲────── Track Rail 1
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│
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├── 1kΩ ──┬──── GPIO 35 (ADC - ACK Detect)
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│ 10kΩ
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│ │
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LM18200 OUT2 ──→ ───┴──────────┴──── Track Rail 2 (GND)
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```
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**How it Works:**
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- **DC Analog Mode**: GPIO 18 outputs PWM for speed, GPIO 19 sets direction
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- **DCC Digital Mode**: GPIO 18 outputs DCC signal A, GPIO 19 outputs DCC signal B (inverted)
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- The LM18200 amplifies whichever signal type to track voltage
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- GPIO 23 (BRAKE) can force both outputs LOW for emergency stop
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- **Programming Track**: Current sense resistor (0.1Ω) detects 60mA ACK pulses from decoder
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### 2. 2-Rail/3-Rail Relay Module
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```
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ESP32 GPIO 4 ──→ Relay Module Signal Input
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ESP32 GND ──→ Relay Module GND
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ESP32 5V ──→ Relay Module VCC
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```
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**Relay Outputs:**
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Configure the relay to switch between 2-rail and 3-rail track wiring:
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- **2-Rail Mode** (Relay OFF): Standard two-rail configuration
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- **3-Rail Mode** (Relay ON): Center rail + outer rails configuration
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### 3. Power Supply
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The ESP32-2432S028R can be powered via:
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- **USB-C**: 5V from USB (programming and operation)
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- **5V Pin**: External 5V power supply (500mA minimum)
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**Recommended Setup:**
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```
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12-18V Power Supply ──→ DC-DC Buck Converter ──→ 5V @ 1A ──→ ESP32 5V Pin
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└──→ Motor Controller Power
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└──→ DCC Booster Power
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```
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## Pin Summary Table
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| Connection | ESP32 Pin | External Device | Notes |
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|------------|-----------|-----------------|-------|
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| PWM/DCC_A | GPIO 18 | LM18200 PWM | DC mode: 20kHz PWM / DCC mode: DCC signal A |
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| DIR/DCC_B | GPIO 19 | LM18200 DIR | DC mode: Direction / DCC mode: DCC signal B |
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| Brake | GPIO 23 | LM18200 BRAKE | Active LOW brake / Emergency stop |
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| Relay Control | GPIO 4 | Relay Module IN | HIGH=3-Rail |
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| ACK Detect | GPIO 35 | Current Sense | ADC input for programming track ACK |
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| Ground | GND | All GNDs | Common ground |
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| Power | 5V | Logic Power | 500mA-1A |
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## Safety Notes
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⚠️ **IMPORTANT SAFETY WARNINGS:**
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1. **Electrical Isolation**: Keep low-voltage control circuits (ESP32) separated from high-voltage motor/track circuits
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2. **Common Ground**: Ensure all components share a common ground reference
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3. **Power Rating**: Motor controller must be rated for your locomotive's current draw
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4. **Fusing**: Install appropriate fuses on track outputs
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5. **Emergency Stop**: Implement physical emergency stop button if needed
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6. **Polarity**: Double-check DCC booster polarity before connecting to track
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## Track Connection
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The LM18200 outputs connect directly to the track in both modes:
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```
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LM18200 OUT1 ──→ Track Rail 1
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LM18200 OUT2 ──→ Track Rail 2
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```
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**Operation:**
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- **DC Mode**: LM18200 outputs PWM voltage (polarity sets direction)
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- **DCC Mode**: LM18200 outputs amplified DCC square wave signals
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- Same physical connections, different signal types
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## Testing Procedure
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1. **Power Up Test**
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- Connect only USB power
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- Verify display shows UI
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- Touch screen should be responsive
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2. **Relay Test**
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- Toggle 2-Rail/3-Rail button
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- Listen for relay click
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- Verify relay LED changes state
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3. **DCC Signal Test** (use oscilloscope)
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- Select DCC mode
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- Power ON
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- Measure GPIO 18 and 19 for square wave signals
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- Verify ~58μs for '1' bits, ~100μs for '0' bits
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- Signals should be inverted relative to each other
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- Check LM18200 outputs for amplified signals (track voltage)
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4. **DC Motor Test** (without load)
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- Select DC Analog mode
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- Power ON
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- Adjust speed slider
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- Measure PWM on GPIO 18 with multimeter (average voltage should increase with speed)
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- Measure LM18200 outputs for amplified PWM
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5. **Track Test** (with locomotive)
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- Start with low speed (10-20%)
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- Gradually increase speed
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- Test direction change
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- Verify emergency stop (Power OFF button)
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## Troubleshooting
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| Problem | Possible Cause | Solution |
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|---------|----------------|----------|
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| Display blank | No power | Check USB/5V power connection |
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| Touch not working | Wrong calibration | Adjust TS_MIN/MAX values in code |
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| No DCC signal | Not powered on | Press Power button in UI |
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| Motor not running | Wrong mode | Verify DC Analog mode selected |
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| Relay not switching | No 5V power | Check relay module power |
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| Erratic behavior | Ground loop | Ensure single common ground point |
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## Component Recommendations
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### H-Bridge Driver (DC & DCC):
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- **LM18200T** (3A continuous, 6A peak) - **RECOMMENDED**
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- Single chip handles both DC and DCC modes
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- Built-in thermal shutdown
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- Built-in current limiting
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- **L298N module** (2A per channel)
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- Readily available, inexpensive
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- Less efficient than LM18200
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- **BTS7960 motor driver** (43A capable)
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- Overkill for most model trains
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- Good for large scale locomotives
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### Relay Module:
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- 5V single-channel relay module
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- Optocoupler isolated
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- Active HIGH trigger
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## Schematic Reference
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```
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┌─────────────────┐
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│ ESP32-2432S028R│
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│ (Built-in) │
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│ - TFT Display │
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│ - Touch Screen │
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└────────┬────────┘
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│
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┌───────────────┬────────┼────────┬───────────────┐
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│ │ │ │ │
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GPIO 17 GPIO 16 GPIO 18 GPIO 19 GPIO 4
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(DCC_A) (DCC_B) (PWM) (DIR) (RELAY)
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│ │ │ │ │
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┌─────▼─────┐ │ │ │ ┌─────▼─────┐
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│ DCC │◄────────┘ │ │ │ Relay │
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│ Booster │ │ │ │ Module │
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└─────┬─────┘ │ │ └─────┬─────┘
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│ ┌─────▼────────▼─┐ │
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│ │ Motor Driver │ │
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│ │ (LM18200) │ │
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│ └────────┬───────┘ │
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│ │ │
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┌─────▼──────────────────────────┼─────────────────────▼─────┐
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│ Track Output │
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│ (DCC or DC Analog depending on mode selection in UI) │
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└──────────────────────────────────────────────────────────────┘
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```
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