Helix PCB Group Buy

[gmbartlett]

The Helix system is finally ready to be released to the group. The Helix is a much improved version of the Prop 128 v2 (http://www.doityourselfchristmas.com/forums/showthread.php?t=4697).

Some of the many improvements are:
1) Integrated the MP3 player onto the main board
2) Integrated the SD card socket onto the main board
3) Reduced the overall number of suppliers and eliminated the long lead time items
4) Reduced the overall cost of the system
5) Now compatible with the standard 5vdc current sink SSR boards
6) Firmware is field upgradable without any additional programmers
7) The system automatically configures the XBee radio
8) The AC zero crossing circuit will work with 120VAC and 240VAC without having to change any of the components.

There are several more minor improvements also. While there are several more firmware upgrades I would like to develop I feel the system is ready for general use. The current version of the firmware works reliable in both Mode 1 and Mode 2 with 128 channels. I have laid out the framework to greatly expand this capability. The biggest obstacle I have is there is only one Helix system in existence at this time. I plan to get at least two more systems with this group buy. Once these systems are built I plan to expand the firmware to easily operate 256 channels in Mode 2 and over 32,000 channels in Mode 1.

I've searched around with the help of David Jones (ukewarrior) to try and find the best price for the PCBs. I found out there is a distinct price break point for the boards. So for this first release I am not going to run a traditional Co-op. Instead I've decided to make this a minimum qty purchase. I need to sell a minimum of 30 systems in order to reach this price break point. Starting today until 31 May 2009 (or until I have orders for 30 systems) I will be accepting orders. If on 31 May I have not received at least 30 orders I will try to get an updated cost for the boards and then ask those that have placed orders if they still want the system at the higher price. I think I have 7 or 8 systems already sold so I only need about 22 more orders.

The price per system is: $39 + shipping.
Shipping per system, via the US Mail, in the US will be $3.00 and to Australia it will be $6.00

Once the order is placed the board house will take 8 days to make and ship the boards. I would expect to receive them in about a week after that. I will be sorting and shipping the boards as soon as I receive them. You should receive your boards in 3 to 4 weeks after the order is placed.

A system consists of:
1) One main PCB board
2) Three daughter PCB boards
3) One microSD socket
4) One preprogrammed EEPROM (programmed with the boot loader)

The microSD socket is being included with the system because the supplier for the socket stopped carrying it after I had the Helix prototype board made. I’ve been able to acquire a sufficient number of the sockets from the manufacturer to support this group buy. The original supplier was charging $3.95 ea but I’m selling them for $2.00 ea.

The preprogrammed EEPROM is being provided so that you will not have to purchase a Prop Plug. The Prop Plug is the USB interface used to program the Propeller chip via the in circuit programming port. The Prop Plug costs $25.00, the EEPROM only about $1.00. The boot loader program on the EEPROM will allow the main firmware to be loaded on the microSD card. Any future updates to the firmware can be uploaded by changing the file on the microSD card.

The remaining parts to fully populate the boards are not included in this group purchase. David Jones (ukewarrior) has mentioned that he may be willing to run a parts group buy for the remaining items. He will be posting details on this in the near future.

The Helix main board has four components that are surface mount devices, three RS-422 drivers and the microSD socket. For those that don't think they can hand solder SMT I am offering an additional service. I will provide the parts and solder them to the main board for an additional $15.00. This service will add about one week to the delivery schedule.

I am developing an assembly manual that will be available for download before the boards are available.

I would prefer to do this by Money Orders instead of using Pay Pal in order to save the processing fees. If someone really wants to use PayPal then there will be an additional $1.50/system processing fee.

If you would like to order a system please send an email to orders@helixlightcontroller.com. In the email include the number of systems you would like and if you want me to provide and solder the SMT components. Additionally please provide your mailing address and if you will be paying by money order or PayPal.

Once I receive your email I will reply with payment information. My plan is to collect the money at the time of the order. If the minimum order quantity is not reached and you decide not to pay the higher price I will refund the money.

Current Order List:

gmbartlett – 1 paid
wjohn – 2 paid
Dan Nilson – 1 paid
Roger Phillips - 4 paid
random_rodder - 3 paid
Corby Self - 1 paid
schujk - 2 paid
Tabor Kelly - 2 paid
rlilly - 1 paid
rollie66 - 1 paid
budude - 1 paid
ukewarrior - 1 paid
esemanteiv - 2 paid
Reddy_Kilowatt - 1 paid
dgreen - 2 paid
tlorek - 1 paid
Jason Huff - 1 paid
Chris Foley - 1 paid
RPM - 1 paid
Gary Gaskill - 1 paid




Total - 30

Group Buy Rules and Other Various Legal Mumbo Jumbo

By participating in this Group Buy all participants agree to release www.doityourselfchristmas.com, its Owners, Administrators, Moderators or any other staff of any and all liability and waive all rights I may have under all laws and governing bodies. By posting in this thread you agree you are entering a binding contract between the Organizer and the Participant.

[rlilly]

Greg, sign me up for 1 system, thanks!

[Warlock]

Just a quick question about these boards....What is the typical cost to populate these boards ???
Thanks
Joe...

[dgreen]

Hey Greg,
I just saw this.
I will read through it tonight and post back but you know I am in!

By the way, I just got my copy of nuts and volts.
congrats!

for those of you who do not know, Greg won an award for the design of this board and is on the (back) cover of this months nuts and volts.

[gmbartlett]

Just a quick question about these boards....What is the typical cost to populate these boards ???
Thanks
Joe...

Good question. I've been meaning to post the BOM but it kept slipping my mind.

For the first full system:
Main Board: ~$111.00
Each Daughter Board: ~$17.00
XBee that connects to the PC: ~$61.00

The main board for the second and more systems will be: ~$86.00

The price decrease is due to the fact that you only need the MP3 player and RTC on the first system. If you are only planning on using these in Mode 2, i.e. wireless control via a PC running Vixen, then the main board for the first system would also be ~$86.00.

These prices are based upon purchasing the parts for a single system and don't include shipping costs. David Jones (ukewarrior) has said he would consider a Co-Op purchase for the parts if there was enough interest. The parts would be cheaper via this route.

I've attached the BOM.

[random_rodder]

Hey Greg,

I have a few questions about the communications when using two Helix systems. I realize it's still in the works, so to speak, so it may not all be figured out yet. You've said in a previous post that two systems will synch thru the ZigBee link. On the the BOM it says the following:

Only One Set of These Parts are Needed No Matter How Many Systems You Order:

Description Part #
XBee Pro 2.4Ghz ZigBee Radio 888-XBP24-AWI-001 (item is on the main Helix board)
XBee Explorer USB WRL-08687 (this allows PC to talk to Helix in Mode 2?)
USB miniB Cable CAB-00598

If there is only one radio, regardless of how many systems you build, how will the master send signals to the other Helix units in the yard? Did I miss something somewhere? (quite possible...) Did I misconstrue what you said? Also, is there an addressing scheme for the downstream systems?

Is there a length limit to the cable connecting the main Helix board to the daughter cards?

I apologize if I'm jumping the gun here, I'm just excited about upgrading my capabilities this year. Ten years of static and two years of Olsen 595, I'm ready for dimming!!!


Thanks,

Brian

[rollie66]

Hey Greg,

I have a few questions about the communications when using two Helix systems. I realize it's still in the works, so to speak, so it may not all be figured out yet. You've said in a previous post that two systems will synch thru the ZigBee link. On the the BOM it says the following:

Only One Set of These Parts are Needed No Matter How Many Systems You Order:

Description Part #
XBee Pro 2.4Ghz ZigBee Radio 888-XBP24-AWI-001 (item is on the main Helix board)
XBee Explorer USB WRL-08687 (this allows PC to talk to Helix in Mode 2?)
USB miniB Cable CAB-00598

If there is only one radio, regardless of how many systems you build, how will the master send signals to the other Helix units in the yard? Did I miss something somewhere? (quite possible...) Did I misconstrue what you said? Also, is there an addressing scheme for the downstream systems?

Is there a length limit to the cable connecting the main Helix board to the daughter cards?

I apologize if I'm jumping the gun here, I'm just excited about upgrading my capabilities this year. Ten years of static and two years of Olsen 595, I'm ready for dimming!!!


Thanks,

Brian


This stumped me for a minute or two until I realized this is the transmitter unit that attaches to your pc. Each Helix has its own Xbee unit as well.


This is post 47 for me. I did not realize it. How many people are aware of the lore of 47?

[rollie66]

It seems like only twelve more until 30. Please dont hesitate until the end. Cant wait for the daughter boards with onboard ssrs as well.

[random_rodder]

XBee Explorer USB WRL-08687 (this allows PC to talk to Helix in Mode 2?)


I guess this is used to allow the PC to talk to the Helix system, in conjunction with an XBee, and each Helix will have a radio. Guess I just got confused...

[gmbartlett]

Hey Greg,

I have a few questions about the communications when using two Helix systems. I realize it's still in the works, so to speak, so it may not all be figured out yet. You've said in a previous post that two systems will synch thru the ZigBee link. On the the BOM it says the following:

Only One Set of These Parts are Needed No Matter How Many Systems You Order:

Description Part #
XBee Pro 2.4Ghz ZigBee Radio 888-XBP24-AWI-001 (item is on the main Helix board)
XBee Explorer USB WRL-08687 (this allows PC to talk to Helix in Mode 2?)
USB miniB Cable CAB-00598

If there is only one radio, regardless of how many systems you build, how will the master send signals to the other Helix units in the yard? Did I miss something somewhere? (quite possible...) Did I misconstrue what you said? Also, is there an addressing scheme for the downstream systems?


Brian,

Thanks for the questions. Rollie66 is correct in that the single XBee radio and USB Explorer is the radio link so the PC can talk with the Helix systems. Each Helix system has its own XBee radio on board also.

I do have a network addressing scheme worked out. It is a little complicated but I will try to explain it briefly.

Two or more Helixes connected together are called a Helix Network. The network uses an 8-bit addressing scheme. In a Helix Network the first Helix system is called the Network Controller. This is the only Helix that has to have the MP3 player and RTC. It is responsible for starting/stopping the show, playing the music and providing the synch signals. Its address is 1.

You will also have a PC running the Helix Network Supervisor software. The software allows you to check on the status of the network, start/pause/stop a show or specific sequence and troubleshoot a malfunctioning Helix. It is called the Network Supervisor and its address is 254.

There is another device that is still in the very early stages of development called the Network Tester. Its address is 253.

All of the other Helix systems on the network are called Network Nodes and they have addresses between 2 and 252 excluding 170. 170 is reserved for the start byte for a Helix message.

Address 0 is reserved for the SOS mode of the controller. If a Helix system encounters a fatal error it will try to default to the SOS mode. In the SOS mode the Network Supervisor can connect to it and request the error code.

The Broadcast address for the network is 255.

This addressing scheme allows up to 32,128 channels to be controlled in one Helix Network.



Is there a length limit to the cable connecting the main Helix board to the daughter cards?

I'm sure there is a length limit but I don't know what it is. I've tested it with a 100' Cat 5e patch cord (the longest one I have) and didn't have any problems. Since it is an RS-422 link it should be good for several hundred feet I believe.

[random_rodder]

Thanks for the answers Greg & rollie66. I was reading the Helix BOM too literally, lol. You've really designed a masterpiece, Greg, that I fully believe would put any current commercial product to shame. I enjoyed cutting my teeth on the Olsen 595, so I can't wait to get my Helix(s) soldered up and tested.

I may not be able to do much decorating this year, but, I'll have a blast getting it ready...

Thanks again,

Brian

[gmbartlett]

I've gotten a little impatient and decided to front the money for the remaining group buy Helix systems. I ordered the boards and should receive them in 2 - 2 1/2 weeks. Until May 31 or I sell out I will still honor the original price for anyone that would like a set. After May 31 the price will go up slightly to cover my miscalculation of my costs.

If you are interested in getting a Helix system this year please send me an email at orders@helixlightcontroller.com

At this time I don't plan on running another group buy for the Helix system this year unless there is substaintial interest in one.

I want to thank everyone that has requested a set and provided prompt payment. You have made this group buy very easy.

[ukewarrior]

Hey Greg,

Any chance of posting the BOM as a .xls or .doc file so we can easily cut and paste it or have a file we can annotate for our own use?

[51fordf2]

David - I'll try to post the BOM...I'm pretty sure this is the correct one...both for the controller, and the daughter boards.

R

[gmbartlett]

That BOM is correct with one minor exception. You will not need to purchace IC2 the I2C EEPROM as it is being provided with the Helix System under this group buy.

[gmbartlett]

Only 7 more Helix systems available in this group buy. If you are interested in one please send an email to orders@helixlightcontroller.com

I've ordered the boards and they should be shipped to me 2 Jun 2009. I will be sending them out as soon as I get them.

[gmbartlett]

I'm sorry but there was an error on the originally posted BOM. For some reason IC1 - IC4, the 74HC4094 chips, were left off of the Daughter board BOM. I've posted an updated BOM here. I'm sorry if this has caused any problems. I will be placing a Mouser order this week, so let me know if I need to order some for you because of this mistake.

[gmbartlett]

Only 6 more systems available in this group buy. I received notice today from the board house that the PCBs should ship 2 Jun 2009. I will start sending them out as soon as I get them.

If you haven't ordered yours yet then send me an email at orders@helixlightcontroller.com

[51fordf2]

Greg - sent you a PM...

Roger

[keebler]

how much is the helix system?

[gmbartlett]

how much is the helix system?

The Helix System that this group buy is selling is just the PCBs, 1 main board and 3 daughter boards. This will give you 128 full dimming channels that can operate in a stand-alone mode, i.e. no need to be connected to a PC to run your show.

The PCB only price per system is: $39 + shipping.
Shipping per system, via the US Mail, in the US will be $3.00 and to Australia it will be $6.00

The parts cost for the first full system:
Main Board: ~$111.00
Each Daughter Board: ~$19.00
XBee that connects to the PC: ~$61.00

The main board for the second and more systems will be: ~$86.00

The price decrease is due to the fact that you only need the MP3 player and RTC on the first system. These prices are based upon purchasing the parts for a single system and don't include shipping costs.

You will also need SSR boards. The Helix is compatible with any of the standard DIY 4-channel SSR boards.

You can read more about the Helix at www.helixlightcontroller.com

If you have any specific questions or concerns then let me know

Thank you for showing interest in the Helix.

[gmbartlett]

Only 4 Helix systems left in this group buy.

[gmbartlett]

Still have 4 Helix systems remaining in this group buy.

[gmbartlett]

The PCB's arrived today and they look great. I also received the Mouser order with the EEPROMs. I will start programming the EEPROMs and packaging the boards this weekend. They should be in the mail early next week for the people that didn't request the SMD Soldering Service.

I've ordered the Surface Mount RS-422 TX chips from Maxim-IC but they appear to be back ordered. I'm still waiting on an updated delivery date from Maxim-IC. For the people that requested the SMD Soldering Service I will solder on the microSD Card Socket now. Once I receive the Maxim-IC order I will solder those chips on ASAP and get them shipped to you.

I will keep everyone updated as I get new info.

There are still 4 Helix systems available if anyone would like to join in on this group buy.

[ukewarrior]

Great News Greg!

[gmbartlett]

Another system was spoken for, now there are only 3 Helix systems left in this group buy.

[random_rodder]

Thanks for all the updates, Greg!!

[budude]

Awesome! I have my SSRs nearly completed (just need some backordered fuse holders from Mouser) so I'll be ready for it!

Brian

[gmbartlett]

Two more systems have been spoken for. Only ONE systems left in this Group Buy.

[ukewarrior]

oooohhhhhhhhhhhhhh its getting scary now......

Who will be the lucky winner of the LAST Helix system ?????????!!!!?????

[51fordf2]

As mom used to say, "Four's enough for ANY pig!"...

:)

R

[RPM]

oooohhhhhhhhhhhhhh its getting scary now......

Who will be the lucky winner of the LAST Helix system ?????????!!!!?????



That would be me ;) I'll take the last one if it's still available.

Robert

[gmbartlett]

That would be me ;) I'll take the last one if it's still available.

Robert

Robert,

Please send me an email at orders@helixlightcontroller.com and specify if you would like the SMD Soldering Service. I will then send you a PayPal invoice.

[51fordf2]

That would be me ;) I'll take the last one if it's still available.

Robert

Robert - thanks!! You saved me from a life of living in the shop...if I had gotten a fifth Helix, that's where I would have been living!! Of course, the good side is, there's LOT'S more room over there...

:)

Roger

[gmbartlett]

The Maxim-IC order arrived today and all of the chips are in the shipment. (So much for the four week lead time.) For all of the people that ordered the SMD soldering service I've already soldered the microSD Socket to the boards. I will start soldering the RS-422 TX chips tomorrow night. Hopefully I will be completed with this task within a week.

[51fordf2]

Woooo-wooooo!! You da man, Greg!

Roger

[RPM]

Robert - thanks!! You saved me from a life of living in the shop...if I had gotten a fifth Helix, that's where I would have been living!! Of course, the good side is, there's LOT'S more room over there...

:)

Roger

Roger... so is living in the shop is a bad thing?

Seems that lots of us do that already (or it would seem that way) ;)


Robert

[51fordf2]

Actually, I have most everything set up in the dining room and parlor - piled 2 feet high, on the kitchen table, and another two feet high, on a huge desk. I also have 4 of the kitchen tables filled...oh yeah, and the rocker in the entry. As well as 4 boxes of cat5 on the floor. I do all my etching and drilling, and assembly in the kitchen itself, so half the counter space is taken up, too...actually, my wife would LOVE it if I'd move to the shop...but, I'm restoring a '51 Ford F2 pickup in there...

'51 Ford, when I got it (http://crbest.com/testone.swf)

'51, how it looks now... (http://crbest.com/bodywork/)

Oh well, at least I stay busy!!

Roger

[budude]

Good deal Greg - my SSRs are getting lonely waiting for their new "master"! :D

Brian


The Maxim-IC order arrived today and all of the chips are in the shipment. (So much for the four week lead time.) For all of the people that ordered the SMD soldering service I've already soldered the microSD Socket to the boards. I will start soldering the RS-422 TX chips tomorrow night. Hopefully I will be completed with this task within a week.

[gmbartlett]

All of the Helix systems have been spoken for including one of mine. The group buy is now closed. I will be getting the systems out to everyone ASAP. Please stay tuned for further updates.

Thank you everyone for participating!

[gmbartlett]

Weekly update: I've shipped out all of the boards that I can at this time. I'm still waiting on a couple of backordered items. Supplier said they should arrive this week or next. I will ship out the remainder of the boards when these items arrive.

[g2ktcf]

Actually, I have most everything set up in the dining room and parlor - piled 2 feet high, on the kitchen table, and another two feet high, on a huge desk. I also have 4 of the kitchen tables filled...oh yeah, and the rocker in the entry. As well as 4 boxes of cat5 on the floor. I do all my etching and drilling, and assembly in the kitchen itself, so half the counter space is taken up, too...actually, my wife would LOVE it if I'd move to the shop...but, I'm restoring a '51 Ford F2 pickup in there...

'51 Ford, when I got it (http://crbest.com/testone.swf)

'51, how it looks now... (http://crbest.com/bodywork/)

Oh well, at least I stay busy!!

Roger

I orginally set up everything on the kitchen table...did not take long to be "banished" into the garage!

[51fordf2]

I orginally set up everything on the kitchen table...did not take long to be "banished" into the garage!

Well, my wife is VERY tolerant of my "idiosyncrasies"...we have lasted all these years, because we only have ONE thing in common....we both love ME!!!

Actually, she told me she wants it cleared off by Thanksgiving, and I told her, if it's NOT, then I don't have a show!! So BETTER be cleared off by then...

R

[Wombat]

Got my Main Board chip and socet today looks very nice thanks Greg

Wombat

[gmbartlett]

All boards have been shipped out. I want to thank everyone for their participation and patience. It was a learning experience for me and I promise it will be better next time.

Unless there is a real interest, I don't plan on running another Helix group buy until early next year.

If anyone needs assistance with assembly or set up please check the Helix Forum or email me a Greg@helixlightcontroller.com

This Group Buy is now Closed.