Detailed assembly and construction instructions for building the ESCTL Door Controller board and associated components.

Construction Details

The wiring logic depends on whether you are using the Serial (RS232) or Ethernet version of the controller.

  • Serial Version: Connect TX-TX and RX-RX between the RS232 driver and the Arduino.
  • Ethernet Version: Connect TX-RX and RX-TX between the Ethernet driver and the Arduino.

Suggested Wiring Order

We have found the table below to show a good order to complete the wiring between internal components (you may connect in any order, of course)

Refer to the Pinouts Reference for specific Arduino pin assignments.

Connection Cable Type Routing
5V Power 1 x F-F 5V PSU → Ethernet (Vdd)
Main Inputs 5 x M-F vIn/GND/Reader(D0,D1)/Voltage_Sense → Arduino
Data Communication 3 x M-F GND(Ethernet) → GND(Arduino)
TX(Ethernet) → RX(Arduino)
RX(Ethernet) → TX(Arduino)
Configuration 1 x M-F Arduino CFG → Ethernet (Not yet used)
Relay Control 4 x F-F Relay → Arduino (1 pin N/C)

Partially completed door node Inside of a partially completed door node (missing the Arduino, Dupont connections, and bootlace ferrules in this photo).

Connection Board

  • Cable Lengths: Brown/Blue cables should be cut to 75mm.
  • Voltage Sense:
    • 4k7 resistor connected to GND.
    • 15k resistor connected to Vin.
    • Common junction connected to Arduino pin A3.
  • Flyback Protection: Use a 1N4004 diode. The stripe (cathode) must be connected to V+(lock) and the other end to GND.

Connection Board The completed Connection Board.

Bi-colour LED

For visual status feedback, use a bi-colour LED (CPC/Farnell part SC07647 suggested).

  • Cabling: Black/Red/Green cable cut to 30cm.
  • Resistor: 120R.
  • Pinout (LED SC07647):
    • Pin by flat edge: Red
    • Centre pin: Ground
    • Pin opposite flat edge: Green

Network Interface Setup (USR TCP-232)

Before the controller can communicate, the USR TCP-232 module itself must be configured with appropriate IP settings. This will also show you its MAC address.

USR TCP-232 Settings Example IP settings for the USR TCP-232 module. This interface is also where you can find the hardware MAC address of the network card.

Board configuration (MAC, Serial)

After assembly, you must configure the door controller via the console to match your hardware’s unique identifiers.

  1. Connect to the board via the serial console.
  2. Set the MAC address to match your network card: set mac 00-FA-0F-AB-12-34
  3. Set the board serial number: set serial 123

Enclosure & Front Cover

  • LED Hole: Drill a 2mm hole using a template (approximately 18mm in from each edge).
  • Finishing: File down the head of the LED for maximum light diffusion through the enclosure cover.

Front Label Positioning Positioning of the label on the front of the node, showing the hole for the status LED.

LED Internal Positioning Positioning of the status LED inside the node cover.

LED Diffusion How to file down the head of the LED to ensure maximum light diffusion.