Initialisation depot
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ESP32/DCC-Bench/WIRING.md
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312
ESP32/DCC-Bench/WIRING.md
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# Simplified Wiring Diagram
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## The Key Insight: One Driver for Everything! 🎯
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**You only need ONE LM18200 H-Bridge driver** - it handles both DC and DCC modes.
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The ESP32 just sends different signals to the same pins depending on which mode you select:
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```
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ESP32-2432S028R
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┌─────────────┐
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│ │
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GPIO 18 ─┤PWM / DCC_A │───┐
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GPIO 19 ─┤DIR / DCC_B │───┤
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GPIO 23 ─┤BRAKE │───┤
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GPIO 4 ─┤RELAY │───┼──→ To Relay Module
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GPIO 35 ─┤ADC (ACK) │◄──┼──→ From ACS712 OUT
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GND ─┤ │───┤
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5V ─┤ │───┤
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└─────────────┘ │
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│
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↓
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LM18200 H-Bridge Module
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┌──────────────┐
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GPIO 18 ───┤ PWM Input │
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GPIO 19 ───┤ DIR Input │
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GPIO 23 ───┤ BRAKE │
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GND ───┤ GND │
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5V ───┤ VCC (logic) │
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12-18V ───┤ VS (power) │
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│ │
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│ OUT1 OUT2 │
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└───┬──────┬───┘
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│ │
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↓ ↓
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ACS712 Current Sensor
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┌──────────────┐
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OUT1 ───┤ IP+ │
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│ │
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To Track ◄──┤ IP- OUT ├──→ GPIO 35 (ADC)
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Rail 1 │ │
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│ VCC GND ├──→ GND
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5V ───┤ │
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└──────────────┘
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│
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↓
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Track Rail 1
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│
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(Rail 2 from OUT2)
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```
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## How It Works
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### DC Analog Mode
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When you select **DC Analog** mode in the UI:
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- GPIO 18 outputs **20kHz PWM** (0-100% duty cycle for speed)
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- GPIO 19 outputs **HIGH or LOW** (sets direction: FWD or REV)
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- LM18200 amplifies this to create variable DC voltage on the track
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- Your DC locomotive responds to the voltage
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- ACS712 monitors current (optional - can display on screen)
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### DCC Digital Mode
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When you select **DCC** mode in the UI:
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- GPIO 18 outputs **DCC Signal A** (square wave: 58μs or 100μs pulses)
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- GPIO 19 outputs **DCC Signal B** (inverted version of Signal A)
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- LM18200 amplifies these to create DCC waveform on the track
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- Your DCC decoder locomotive responds to the digital commands
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- ACS712 monitors current for normal operation
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### DCC Programming Mode
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When you press **[PROG]** button in DCC mode:
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- GPIO 18/19 send **service mode packets** (22-bit preamble)
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- Decoder receives CV programming commands
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- Decoder responds with **60mA ACK pulse** for 6ms if command valid
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- ACS712 detects current spike and sends voltage to GPIO 35
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- ESP32 reads ADC and confirms successful programming
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- UI shows "Verified!" or "Failed - No ACK"
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## Complete Connection List
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### LM18200 Module to ESP32
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| LM18200 Pin | ESP32 GPIO | Purpose |
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|-------------|------------|---------|
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| PWM Input | 18 | Speed (DC) / DCC Signal A (DCC) |
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| Direction Input | 19 | Direction (DC) / DCC Signal B (DCC) |
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| Brake Input | 23 | Emergency stop |
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| GND | GND | Ground reference |
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| VCC (logic) | 5V | Control logic power |
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### LM18200 Module Power & Outputs
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| LM18200 Pin | Connection | Purpose |
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|-------------|------------|---------|
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| VS (motor power) | 12-18V supply + | High current power |
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| GND (power) | 12-18V supply - | Power ground |
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| OUT1 | ACS712 IP+ | To current sensor |
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| OUT2 | Track Rail 2 | Direct to track |
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### ACS712 Current Sensor Module
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| ACS712 Pin | Connection | Purpose |
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|------------|------------|---------|
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| IP+ | LM18200 OUT1 | Current input (from driver) |
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| IP- | Track Rail 1 | Current output (to track) |
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| VCC | 5V | Sensor power |
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| GND | GND | Ground reference |
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| OUT | GPIO 35 (ADC) | Analog current reading |
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**ACS712 Variants:**
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- **ACS712-05A**: ±5A max (recommended for small locomotives)
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- **ACS712-20A**: ±20A max (for larger locos or multiple)
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- **ACS712-30A**: ±30A max (overkill, but works)
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**Output Voltage:**
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- At 0A: 2.5V (Vcc/2)
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- Sensitivity:
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- 5A model: 185 mV/A
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- 20A model: 100 mV/A
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- 30A model: 66 mV/A
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- ACK Detection (60mA): ~2.5V + (0.06A × sensitivity)
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### Relay Module (2-rail/3-rail switching)
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| Relay Pin | ESP32 GPIO | Purpose |
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|-----------|------------|---------|
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| Signal IN | 4 | Relay control |
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| VCC | 5V | Relay power |
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| GND | GND | Ground |
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### Power Supply Connections
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```
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12-18V Power Supply
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├─→ LM18200 VS (motor power)
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├─→ DC-DC Buck Converter → 5V → ESP32 + Relay + LM18200 VCC + ACS712 VCC
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└─→ GND (common ground for all modules)
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```
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## ACS712 Current Sensor Details
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### Why ACS712?
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✅ **Hall-effect sensor** - Electrically isolated, no voltage drop
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✅ **Analog output** - Easy to read with ESP32 ADC
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✅ **Bi-directional** - Measures current in both directions
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✅ **Module available** - Pre-built boards with 5V supply
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✅ **ACK Detection** - Sensitive enough to detect 60mA programming pulses
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### Wiring the ACS712
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The ACS712 goes **in series** with ONE track rail:
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```
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LM18200 OUT1 ──→ [ACS712 IP+]──[IP-] ──→ Track Rail 1
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│
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[OUT] ──→ GPIO 35 (ESP32 ADC)
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│
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[VCC] ──← 5V
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│
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[GND] ──← GND
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LM18200 OUT2 ──────────────────────────→ Track Rail 2
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```
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### Reading Current in Software
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The ACS712 outputs an analog voltage proportional to current:
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```cpp
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// ACS712 5A model example
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#define ACS712_PIN 35
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#define ACS712_SENSITIVITY 0.185 // 185 mV/A for 5A model
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#define ACS712_ZERO 2.5 // 2.5V at 0A (Vcc/2)
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float readCurrent() {
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int adcValue = analogRead(ACS712_PIN);
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float voltage = (adcValue / 4095.0) * 3.3; // Convert to voltage
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float current = (voltage - ACS712_ZERO) / ACS712_SENSITIVITY;
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return current; // Returns current in Amps
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}
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```
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### ACK Detection with ACS712
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For DCC programming track ACK (60mA pulse):
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```cpp
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bool DCCGenerator::waitForAck() {
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#define CURRENT_SENSE_PIN 35
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#define ACS712_ZERO_VOLTAGE 2.5
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#define ACS712_SENSITIVITY 0.185 // For 5A model
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#define ACK_CURRENT_THRESHOLD 0.060 // 60mA in Amps
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unsigned long startTime = millis();
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// Wait up to 20ms for ACK pulse
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while (millis() - startTime < 20) {
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int adcValue = analogRead(CURRENT_SENSE_PIN);
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float voltage = (adcValue / 4095.0) * 3.3;
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float current = abs((voltage - ACS712_ZERO_VOLTAGE) / ACS712_SENSITIVITY);
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// If current spike detected (60mA+)
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if (current > ACK_CURRENT_THRESHOLD) {
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Serial.println("ACK detected!");
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return true;
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}
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delayMicroseconds(100);
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}
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Serial.println("No ACK");
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return false;
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}
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```
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### Calibration
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Before using ACK detection, calibrate the zero point:
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1. **Power on** with no locomotive on track
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2. **Read GPIO 35** multiple times and average
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3. **Calculate zero voltage** (should be ~2.5V)
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4. **Update ACS712_ZERO** in code if needed
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```cpp
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// Calibration routine (run once)
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void calibrateCurrentSensor() {
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float sum = 0;
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for (int i = 0; i < 100; i++) {
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int adc = analogRead(35);
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float voltage = (adc / 4095.0) * 3.3;
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sum += voltage;
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delay(10);
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}
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float zeroVoltage = sum / 100.0;
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Serial.printf("ACS712 Zero Point: %.3fV\n", zeroVoltage);
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}
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```
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## Why This Works
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The LM18200 is just an amplifier. It doesn't care if you're feeding it:
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- PWM signals (for DC speed control)
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- DCC square waves (for digital commands)
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It simply takes the 3.3V logic signals from the ESP32 and amplifies them to track voltage (12-18V).
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**In DC mode**: The amplified PWM creates variable DC voltage
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**In DCC mode**: The amplified square waves create the DCC signal
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**In Programming mode**: The ACS712 detects decoder ACK pulses
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### Benefits of Using ACS712
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✅ **No voltage drop** - Hall-effect sensor doesn't load the circuit
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✅ **Isolated measurement** - Safe for ESP32 ADC input
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✅ **Both directions** - Works with forward/reverse current
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✅ **Module form** - Easy to wire, includes filtering capacitors
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✅ **DCC ACK capable** - Sensitive enough for 60mA detection
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✅ **Current monitoring** - Can display real-time current on UI
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✅ **Overcurrent detect** - Software can trigger emergency stop
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## Safety Notes
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✅ **Always power OFF before switching modes** (automatic in the UI)
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✅ **Common ground** - All GND connections must be tied together
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✅ **Heat sink** - LM18200 can get hot, use appropriate heat sinking
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✅ **Fusing** - Add fuse on track output for overcurrent protection
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✅ **ACS712 rating** - Use 5A model for most O-scale locos, 20A for larger
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✅ **Short circuit** - Monitor current and auto-shutdown on excessive draw
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## Shopping List
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### Required Components
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- ✅ **ESP32-2432S028R** module (includes display + touch)
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- ✅ **LM18200 H-Bridge module** (or bare IC + heatsink)
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- ✅ **ACS712 current sensor module** (5A or 20A version)
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- ✅ **5V relay module** (for 2-rail/3-rail switching)
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- ✅ **12-18V power supply** (2A minimum)
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- ✅ **DC-DC buck converter** (12-18V to 5V, 1A)
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- ✅ **Wires** (22-24 AWG for logic, 18-20 AWG for track)
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- ✅ **Fuse holder** + appropriate fuse
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### Optional but Recommended
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- 🔧 Heatsink for LM18200 (if using bare IC)
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- 🔧 Terminal blocks for easy track connections
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- 🔧 Emergency stop button (wired to GPIO 23 or power)
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- 🔧 Case/enclosure for professional finish
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## No Separate DCC Booster Needed!
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You do **NOT** need:
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- ❌ Separate DCC booster circuit
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- ❌ Different outputs for DC vs DCC
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- ❌ Mode selection switches in hardware
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- ❌ Separate programming track booster
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- ❌ Complex current sensing circuits (ACS712 handles it!)
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Everything is handled in software by the ESP32 touchscreen UI.
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## Connection Summary
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**Minimum wiring** for full functionality:
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1. **ESP32 to LM18200**: 5 wires (GPIO 18, 19, 23, GND, 5V)
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2. **LM18200 to ACS712**: 2 wires (OUT1 to IP+, IP- continues to track)
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3. **ACS712 to ESP32**: 3 wires (OUT to GPIO 35, VCC to 5V, GND)
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4. **ESP32 to Relay**: 3 wires (GPIO 4, 5V, GND)
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5. **Power supply**: 12-18V to LM18200, 5V to all logic
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Total: **~16 connections** for a complete dual-mode test bench with programming!
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---
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**Bottom Line**: Wire up ONE LM18200 + ONE ACS712, and you get:
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- ✅ DC analog speed control
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- ✅ DCC digital operation
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- ✅ DCC programming track with ACK verification
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- ✅ Real-time current monitoring
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- ✅ Overcurrent protection capability
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