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Bonitron Air Demand Bonitron Air Demand SchedulerScheduler
Design ReviewDesign ReviewVanderbilt Senior DesignVanderbilt Senior Design
Alex BrownAlex BrownAjmer DwivediAjmer Dwivedi
Cory HaughCory Haugh
February 04, 2008February 04, 2008
IntroductionIntroduction
Air Demand Air Demand SchedulerScheduler Reduces peak Reduces peak
power consumptionpower consumption Selects 1 of 2 Selects 1 of 2
HVAC units to run HVAC units to run at a timeat a time
Allows for manual Allows for manual control using user control using user overridesoverrides
ObjectivesObjectives
Production ready prototypeProduction ready prototype Low cost microprocessorLow cost microprocessor RS-232 I/O functionalityRS-232 I/O functionality Identical logic Identical logic All other specifications are to remain All other specifications are to remain
the samethe same Preserve existing packagePreserve existing package
RequirementsRequirements Input PowerInput Power
115VAC, 50/60Hz115VAC, 50/60Hz Control Signals 24 VACControl Signals 24 VAC
InputsInputs Thermostat 1: Air Conditioning 1, Heat 1Thermostat 1: Air Conditioning 1, Heat 1 Thermostat 2: Air Conditioning 2, Heat 2Thermostat 2: Air Conditioning 2, Heat 2
OutputsOutputs Unit 1: Air Conditioning 1, Heat 1Unit 1: Air Conditioning 1, Heat 1 Unit 2: Air Conditioning 2, Heat 2Unit 2: Air Conditioning 2, Heat 2
EnclosureEnclosure NEMA-12 Wall Mountable w/Quick Release Door Latch (10’’ x NEMA-12 Wall Mountable w/Quick Release Door Latch (10’’ x
6’’ x 4’’)6’’ x 4’’) Operating TemperatureOperating Temperature
0 to +40 Degrees Celsius0 to +40 Degrees Celsius Storage TemperatureStorage Temperature
+20 to +65 Degrees Celsius+20 to +65 Degrees Celsius HumidityHumidity
Below 90%Below 90% AtmosphereAtmosphere
Free of Corrosive Gas and DustFree of Corrosive Gas and Dust
ApproachApproach
Extract existing design from Extract existing design from previous group’s documentation and previous group’s documentation and new hardwarenew hardware
Replace FPGA development kit with Replace FPGA development kit with microcontroller microcontroller
Develop PCB design partitioning Develop PCB design partitioning circuit componentscircuit components
Fabricate assemble and test designFabricate assemble and test design
System DiagramSystem Diagram
Main Board
Power Conversion
Signal Conversion
120V AC Power Supply
Thermostat 1
Thermostat 2
Heat
A/C
Controller
Output Relays
Heat
A/C
HVAC 1
HVAC 2
RS232 Conversion
Computer
5V
ON/OFF
ON/OFF
Demand 1
Demand 1
Gnd
PicKit 2 Programmer
Vp
p
PG
D
PG
C
ProgrammingHeader
Vp
p
PG
D
PG
C
RxD
TxD
Vcc Heat
RxD
TxD
RxD
TxD
Gnd
Vpp PGD PGC
RA0RA1RA2RA3RA4
RA0RA1RA2RA3RA4
RD0
RD1
Ribbon Cable
Display Board
LEDs (5)
Control Buttons (2)
D0D1D2D3D4
RD2RD3
D0D1
A\CSignal Gnd
ON\OFF
ON\OFF
RB0
RB1
RD2RD3
Signal Gnd
Signal Gnd
ON/OFF
ON/OFF
Signal Gnd
Signal Gnd
Signal Gnd
Heat
A\CSignal Gnd
Signal Gnd
Signal Gnd
VccGnd
VccGnd
120V AC
System GndAC Neutral
Chassis Gnd
Power Conversion Power Conversion DiagramDiagram
Power Conversion
+5V
Gnd
+18V
Fro
m W
all S
ocke
t To R
est of Board
120V AC
System GndAC Neutral
Chassis Gnd
Power Conversion Power Conversion RequirementsRequirements
Provides conditioned power to Provides conditioned power to Signal Conversion BoardSignal Conversion Board
InputsInputs 115 VAC IN115 VAC IN
OutputsOutputs +18 VDC (nominal) OUT+18 VDC (nominal) OUT +5 VDC OUT+5 VDC OUT
Signal Conversion Signal Conversion DiagramDiagramFrom Power Conversion
To
The
rmos
tat 1
To
Microcontroller
Signal Conversion
ON/OFF
ON/OFFDemand 1
Demand 1
Signal Gnd
Signal Gnd
ON/OFF
ON/OFF
Signal Gnd
Signal Gnd
Gnd
+5
VHeat
A\CSignal Gnd
Signal Gnd
Heat
A\CSignal Gnd
Signal Gnd
To
HV
AC
Units
+18
V
Signal Conversion Signal Conversion Functional RequirementsFunctional Requirements
InputsInputs Thermostats provide 24 VAC upon DemandThermostats provide 24 VAC upon Demand
2 Heat Inputs2 Heat Inputs 2 Cool Inputs2 Cool Inputs
OutputsOutputs Replaces thermostats to HVAC unitsReplaces thermostats to HVAC units 24 VAC sent to HVAC units via relays based on 24 VAC sent to HVAC units via relays based on
decisions made by microcontroller, I/O Board, or decisions made by microcontroller, I/O Board, or user interfaceuser interface
Optical IsolationOptical Isolation Optocouplers isolate and protect microcontroller Optocouplers isolate and protect microcontroller
& I/O Board from outside 24 VAC circuitry& I/O Board from outside 24 VAC circuitry
Signal ConversionSignal Conversion 24 VAC Input from Thermostats24 VAC Input from Thermostats
Conditioned and rectifiedConditioned and rectified Electrically IsolatedElectrically Isolated Sent to microcontroller & I/O Board Sent to microcontroller & I/O Board
If +5 VDC from microcontrollerIf +5 VDC from microcontroller Amplified via Darlington array to turn off relayAmplified via Darlington array to turn off relay
If 0 VDC from microcontrollerIf 0 VDC from microcontroller Grounds output of Darlington array to turn on Grounds output of Darlington array to turn on
relayrelay 24 VAC Output to HVAC24 VAC Output to HVAC
Sent via closed relaySent via closed relay
Microcontroller Microcontroller SelectionSelection
Name Cyclone II FPGACyclone II FPGA HCS12 87C51 PIC16F747
Part Number EP2C35F672C8N MC9S12UF32 P87C51FB-4N PIC16F747
Producer Altera Freescale NXP Microchip
Recurring Cost $99.70 $4.20 $7.80 $3.20
Package 672-FBGA 64-LQFP 40-PDIP 40-PDIP
Programing Software Quartus II
MGTEK MiniIDE Third Party Bundled with PicKit
Programing Hardware Serial Port Cable USB Cable ZIF Socket + USB PicKit 2
Programing Cost $150.00 $100.00 $110.00 $50.00
Programing Language VHDL Assembly \ C Assembly Assembly \ C
Custom Header Y Y N Y
Timers N Y Y Y
RS-232 N Y Y Y
Internal Clock N N Y Y
Non-Volatile Code N Y Y Y
Notes:
Previous groups FPGA, used in FPGA
class at Vanderbilt
Used in microcontroller
s class at Vanderbilt
Microcontroller currently used in Bonitron Board
Lowest Cost to Project
Microcontroller Microcontroller SelectionSelection
Cyclone II FPGACyclone II FPGA High recurring and non recurring costsHigh recurring and non recurring costs Surface mount with 600+ pinsSurface mount with 600+ pins
HCS12HCS12 Surface mountSurface mount High non recurring costsHigh non recurring costs
87C5187C51 Third party programming softwareThird party programming software No C++ supportNo C++ support
Microcontroller Microcontroller
Controller
5V
Demand 1
Demand 1
Gnd
Vpp
PG
D
PG
C
RxD
TxD
Vcc
RxD
TxD
Gnd
Vpp PGD PGC
RA0RA1RA2RA3RA4
RA0RA1RA2RA3RA4
RD0
RD1
RD2RD3
ON\OFF
ON\OFF
RB0
RB1
RD2RD3
To LE
Ds
(I/O B
oard) F
rom B
uttons (I/O
Board)
To C
omputer (D
B-9)
To R
elays (Signal
Processing
)
From Programming Header
Fro
m P
ower
C
onve
rsio
nF
rom
The
rmos
tats
(S
igna
l Pro
cess
ing)
Development ApproachDevelopment Approach
Programmable microcontroller Programmable microcontroller Internal UART Internal UART Internal timerInternal timer Internal oscillatorInternal oscillator
Compatible with original Compatible with original microcontroller (40 pin DIP)microcontroller (40 pin DIP)
Use PICkit 2 programmer and Use PICkit 2 programmer and development kit to code development kit to code microcontrollermicrocontroller
Development Development MethodologyMethodology
User will write the User will write the application application program in C or program in C or assembly codeassembly code
On-board storageOn-board storage RAMRAM
Configuration Configuration retained as long retained as long as the power is onas the power is on
FlashFlash Store program Store program
code in non code in non volatile memoryvolatile memory
MPLAB IDE Development MPLAB IDE Development SoftwareSoftware
Software provided by Microchip for Software provided by Microchip for programming PIC microcontrollersprogramming PIC microcontrollers
Procedure:Procedure: Write code in assembly languageWrite code in assembly language Program microcontrollerProgram microcontroller Test functionalityTest functionality
Apply test inputs and observe outputsApply test inputs and observe outputs Design test strategy for all possible casesDesign test strategy for all possible cases
PICkit 2 PICkit 2
Hardware Hardware programmer for PIC programmer for PIC microcontrollersmicrocontrollers
USB programmableUSB programmable Connects via 6 pin Connects via 6 pin
header on PCBheader on PCB Packaged with Packaged with
starter kit for starter kit for testingtesting
RS-232RS-232
Graphical user interface for control Graphical user interface for control of overrides and timersof overrides and timers Parallels functionality of previous Parallels functionality of previous
override design override design Replaces variable resistors with Replaces variable resistors with
programmable timing capabilities programmable timing capabilities Allows user to program timers Allows user to program timers
without physically manipulating the without physically manipulating the componentscomponents
Programming RS-232Programming RS-232
GUI done using Visual BasicGUI done using Visual Basic Use feedback loop to perform Use feedback loop to perform
original testingoriginal testing
RS-232 HardwareRS-232 Hardware
Max 232 Max 232 transceiver to transceiver to perform voltage perform voltage conversion conversion between circuitry between circuitry and DB-9and DB-9
Changes voltage Changes voltage range from 0 - 5 range from 0 - 5 VDC to ±15 VDC VDC to ±15 VDC
PCB DesignPCB Design Copied 90% from Copied 90% from
previous PCB layoutprevious PCB layout Added connections Added connections
for new for new microcontroller and microcontroller and serial port serial port componentscomponents
2-sided through 2-sided through hole design allows hole design allows easier trace routing easier trace routing than previous single than previous single sided boardsided board
PCB SoftwarePCB Software
Developed PCB design using Developed PCB design using PCBExpressPCBExpress
No License required No License required Order directly though the siteOrder directly though the site Extensive parts libraryExtensive parts library Ability to design custom component Ability to design custom component
based on datasheet specificationbased on datasheet specification
ApprovalApproval
In order to proceed, we request your In order to proceed, we request your approval of the designapproval of the design
Comments?Comments?
Near Term PlanNear Term PlanHardware DevelopmentHardware Development
Add breakpoints to existing PCB Add breakpoints to existing PCB designdesign
Obtain parts from Bonitron Obtain parts from Bonitron storeroomstoreroom
Order PCBOrder PCB Test circuit partitionsTest circuit partitions AssembleAssemble Test Final productTest Final product
Near Term PlanNear Term PlanSoftware DevelopmentSoftware Development
Develop assembly language codeDevelop assembly language code Refine Visual Basic GUIRefine Visual Basic GUI
Hardware ScheduleHardware Schedule
Obtain all components by February Obtain all components by February 1515thth
Order PCB by February 15Order PCB by February 15thth Have assembled prototype boards by Have assembled prototype boards by
March 1March 1stst
Have full board assembled by March Have full board assembled by March 1414thth
Test till design day Test till design day
Software ScheduleSoftware Schedule
Complete GUI by February 22Complete GUI by February 22ndnd Complete programming of the test Complete programming of the test
board microcontroller by March 1board microcontroller by March 1stst Complete programming of product Complete programming of product
ready prototype board ready prototype board microcontroller by March 14microcontroller by March 14thth
System debug and operational testing System debug and operational testing from March 14 until design dayfrom March 14 until design day