Pokeys: Interface Prosim737 and "PoExtBus"

It is easy to extend number of outputs on a single Pokeys USB card by 80 using PoExtBus interface. All what you need to do is to chain up to 10 8-bit shift registers as per below diagram.

 

Note that I recommend to use TPIC6B595 chip instead of standard 74HC595 as it allows to drive high-current (brightness) LEDs.

As Prosim737 doesn't support PoExtBus yet a simple interface is required. So, I have made very simple application called HPoExtBus which uses FSUIPC offset to exchange the data.

Download: http://chomikuj.pl/Elymaniac/sim737.pl (password: pokeys)

How to:

1. Open HPoExtBus.exe.config for editing and update the file as per below:

• your Pokeys card serial number e.g. 25123
  <setting name="cardID" serializeAs="String">
  <value>xxxxx</value>
  </setting>
•  which PoExtBus connection is used: 0=dedicated socket, 1 = pins 35,36,37
  <setting name="cardConnection" serializeAs="String">
   <value>0</value>
   </setting>
• select up to 10 FSUIPC offsets you will be using to communicate with Prosim
  <setting name="offset1" serializeAs="String">
  <value>6740</>
  </setting>

2. Go to Prosim and configure outputs
    example: 0x6740.0 (bit 0) activates port no 7 in HPoExtBus - it is reversed

Remarks:

• HPoExtBus connects to FSUIPC and Pokeys card automatically, it also re-connects in case the card is unplugged or connectivity to FSUIPC is lost;
• it is not required to make any change to Pokeys configuration, this app will activate the PoExtBus;
• click on device\output number to activate it for a while e.g. when testing;
• if connection to FSUIPC is lost all outputs\leds starts blinking;
• FSUIPC offset refresh rate is 200ms, data to Pokeys is sent only when offset value changes.
  

FYI: It's still beta version and I don't expect further development as I wait for Prosim team adding native support for PoExtBus. However, if you have any questions use comments below this post.

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MIP: Part list for EFIS

There is a simple way of making fully functional EFIS panel without using sophisticated encoder embedded into rotary switch and push button. I will be using only standard encoder with button and will have to do some extra programming. As far as I understood Opencockpit's manual for EFIS they use the same architecture. Part list:

• EFIS panel + 9 push buttons
• 9 * tact switche (12x12)
• 2 * two-position ON-OFF-ON switche 
• 4 * encoder with built-in push button
• 10 * bright white led (panel backlit)

EFIS will be connected to FSBUS DIO card, the same running MIP switches. I will also publish the software and configuration in Prosim737 suite.

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FMC: FSBUS for FMC (second card in the cockpit)

Soldering was the first step to assembly FMC panel. There are a few real photos below. Unexpectedly, it started without any issues; great success :-).

If you need more details on architecture, connections and programming select the GENERAL\Electronics section from the menu.

    

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EXTRAS: Boeing 737NG Panel Guide and System Information

Have you ever wondered how particular panels work? I bet you did! So, here you have the link to brilliant Boeing 737NG panel guide with explanations of all the instruments and system functions in the cockpit.

B737NG IntactManual by Rob van Dijk (http://www.rvdijk.nl)

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FMC: The idea and part list

Basically, the heart of each FMC is the software and the panel itself is relatively easy to assembly. Here you have the list of needed parts.

• "dummy" FMC panel with 72 push buttons (from Poldragonet) / 110 EUR
• 5.6" LCD screen (VGA input, resolution 640x480) / 69 USD
• FSBUS electronics / approx 20 EUR
• 72 tact switches
• 3/5 leds
• 10 white leds (high-brightness) to back-lit the keyboard 

A long time ago I purchased dummy FMC from Poldragonet and the plan was to use it on FO side. But now, I have changed my mind and will try to make it fully functional. All buttons will need to be unglued... 

    

The LCD 5.6" screen was ordered via Alieexpress, click here to see the item page. I was positively surprised that there were no shipment nor custom/tax costs and it arrived in 14 days from Hongkong. I read that some people were using LCD screen from PSOne console; forget about it, there is no VGA input and display quality is low.

My FMC will operate on FSBUS electronics. However, single DIO card supports only 64 inputs and remaining keys will be connected to my second card driving MIP switches and EFIS. It's not optimal solution, but I purchased all elements to assembly second DIO card some time ago. It also requires minimum 3 outputs for EXEC (green), FAIL (red), MSG (amber) led annunciators, but my panel will also support OFST and DSPY.

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MIP: Preparations for EFIS

As of now there has been only some preparations done to make EFIS module, see the below picture. It's due to the fact that I was not quite sure whether to buy MCP along with EFIS or not.

Finally, MCP was ordered from OpenCockpits without EFIS module. And, I took a decision that EFIS engraved panel which intend to be dummy panel on FO side would become functional module. The plan is to complete the work by the end of April 2013 and then connect to FSBUS IO card.

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GENERAL: PC System setup and high-level architecture

PC: FSXMain

• Radeon HD 6850 1GB GDDR5(256bit) HDMI/dualDVI, DP, PCI-E
• GIGABYTE GA-P55-USB3, P55, Dual DDR3-2000 MHz, RAID, GLAN, ATX
• Intel Core i7-870, 2.93 GHz, 2.5 GT/s Transfer, 8MB, LGA1156, 45nm
• Patriot GAMING EP 2x2GB 1600MHz DDR3 CL 9.9.9.24
• WD Caviar Blue, 3.5'', 1TB, SATA/300, 7200RPM, 32MB cache
• HEDY 600W ATX 2.2 14cm FAN Activ PFC
• LG SuperMulti SATA DVD+/-R22x,DVD+RW8x,DVD+R DL 16x,SecurDisc

PC 1: FSXPilot

• Intel Pentium 4 CPU 2.8 GHz (dual core)
• Kingston 2x512Mb RAM
• On-board Intel 82865G Graphic Card  
• Seagate Barracuda 7200.7 40 GB, 7200 RPM,3.5"

PC 2: FSXEicas

• Intel Pentium 4 CPU 2.8 GHz (dual core)
• Kingston 2x512Mb RAM
• On-board Intel 82865G Graphic Card  
• Seagate Barracuda 7200.7 40 GB, 7200 RPM,3.5"

PC 3: FSXCoPilot

• none

Displays

• Scenery: 2 x 32" Samsung LCD monitors (1366x768)
• Glasscockpit: 3 x 19" 4:3 LCD no-name flat panels (1024x768)
• CDU: 1 x 5,6" LCD VGA display (800x600)

Audio

• none

Other

• TP-Link TL-WR841N Wireless Router 300Mbps N
• TP-Link TL-WR543G Wireless Router 54Mbps (in AP clinet mode)
• ATX power supply (300W) 5V and 12V for electronics and back-lighting

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MIP: MCP V3 from OpenCockpits

Instead of making the MCP panel on my own I have decided to place an order with OpenCockpits. That was mainly due to high volume of encoders, switches and 7-segment led displays required. Of course, the FSBUS project offers full support for all parts listed above, but I had not time for soldering  :).

In general, there are two different layouts of MCP panels, it's Collins and Honeywell. As you could see below Collins one seems to look more modern, but in real aircraft functionality of both is similar. However, if you wish to obtain  plug'n play unit please look into details as usually not all switches are supported.

    HONEYWELL

    COLLINS (newest)

    (two above screens are taken from ProSim737)

I reviewed a few MCPs available on the market and some have been rejected cause of the price above 1,000 EUR. As I said my choice was V3 from OpenCockpits with white digits, no metallic box (real picture below). Well, I am happy with the quality and I strongly recommend their V3 it's fully functional, easy to configure with ProSim737 via SIOC and relatively cheap, 393 EUR incl. VAT. Real photos below...

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MIP: Sixpack recall annunciators and Master\Fire buttons

It took me around 5h excluding painting time to get two-side 6pack announciators ready for use. Well, it's really cheap, but fully functional solution. Total cost was around 20 EUR for both, excluding electronics as  panels are connected to two FSBUS cards (IO/DO64) which drives MIP switches and announciators.

Before

After

Base (MDF 12mm)
You can copy the idea and adjust the dimensions to the rest of your own glareshield. I recommend to create cardboard template before cutting MDF. Note, it's better to paint after gluing.

Required parts (both sides):

• 16 5mm high-brightness led (14 * yellow, 2 * red) 
• 4 momentary back-lit push buttons (see below)
• 4 tact switches
• 2 engraved back-lit panels 60x30 (own design, click here to download .cdr file)
• 2 5mm transparent plexiglass plates 60x30
• 2 plexiglass plates 80x40

Wiring

RESET_A and RESET_B switches are creating parallel circuit. You can only use one switch, however my six pack engraved front panel is glued on it's left and right side to those switches. So, no matter where you press the front panel one of the switches will click. See the below.

I have been searching Internet for solution which could be used for Master Caution and Fire Warn. Finally I found perfect buttons 32x32mm at NOWY Elektronik. It was just only for 1,5 EUR per one. All you may need to do is to print out labels and place behind color cover. Also, you will have to replace standard bulb which is included by high-brightness led.

Gallery

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MIP: First order and disappointment... a story of Poldragonet MCP

There is a sad story behind my first MCP plug'n play Collins-like layout panel ordered at Poldragonet  (symulatory.com), real picture below.

Unfortunately, the panel was broken at start e.g. encoders were not soldered properly to PCB, switches lock down when pressed, selected digits had different brightness and as far as I remember VSPEED display didn't work at all. It looked like third quality product...

Shit happens, it's just an an electronics...but the problem started from not being able to get in touch with Poldragonet for support. After several weeks of silence I was asked to send it back and stuck with the same problem, again no response for weeks. I gave up, requested a refund and I successfuly received the money back.

My negative recommendation for Poldragonet is because of their horrible approach toward the customers e.g. massive challanges in getting response by email, unanswered phone calls or voice mails, and the most important: delays in delivery measured in months.

Another story is that the MCP panel I received was built on a very old FSBUS v2.2 electronics, not supported natively by ProSim737.

So, think twice before placing the order...

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GALLERY: Weekend in the Netherlands / FSweekend 2012

2-5 November 2012

Well, that was very funny and long weekend in Amsterdam. Actually, it was as it should be in Amsterdam, so nothing to complain at. But, the main purpose was to attend the biggest flight simulation event in Europe FSweekend and visit Aviodrom at Lelystad Airport.

Apart to commercial part and aviodrome there was an opportunity for cockpit builders to show their babies ;-) I can't imagine transporting my cockpit out there, so full respect to those who did it!

See you next time!

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GENERAL: Seats

I tried to repeat a few times here that my project is not necessarily real copy of Boeing 737NG cockpit. This is a hobby and having fun from constructing or virtual flying is much more important than sticking to measurements in millimeters.

So, my seats were taken from regular passenger car. It was Chevrolet PT Cruiser and I find them excellent even if platform had to be created. Note that the best choice are those from a car with driving wheel on right-side. Otherwise, you will  be having challenges in operating radios because seats are equipped with armrests. They have a few more advantages e.g. leather upholstery, built-in two on-off-on momentary switches originally used for heating, electric height regulation or you can change the distance from MIP as in your car. But, the biggest surprise was the price itself, 55 EUR for two!

 

By the way, two heating push buttons are connected to my FSBUS card and I use them to change outside  camera view. The electric height regulation may be a nice feature, but requires dedicated +12V power supply capable to deliver min. 6A per seat.

DON'T BE AN IDIOT! and be very careful when connecting anything to the sockets if your seats are having side airbag. Airbags can easily explode, so it is suggested to remove them before doing any work. See below a few Russian-speaking chuckle-heads and how dangerous it may be for your health.

Here you have a photo showing the distance from the floor, click on it to zoom. It was taken probably in 747, but seems to be also relevant for Boeing 737.

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GENERAL: Materials \ Painting

...for metal or wood

Majority of the cockpit in Boeing 737 is painted on iron gray, RAL 7011. You can easily order it somewhere on Internet, however "Colours: Dark Gray Mat" from Castorama is also good. It's cheap and perfectly matches the other elements painted on RAL 7011. I suggest to take a can of 2.5 liter.

...for metal\plexi surface

You may also need spray for painting small plexi elements or metal parts e.g. screws. Leroy Merlin or Castorama offers great choice of RAL 7011 paints.

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