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Bonitron Air Demand Scheduler Design Review Vanderbilt Senior Design Alex Brown Ajmer Dwivedi Cory Haugh February 04, 2008 Introduction Air Demand Scheduler Reduces peak power consumption Selects 1 of 2 HVAC units to run at a time Allows for manual control using user overrides Objectives Production ready prototype Low cost microprocessor RS-232 I/O functionality Identical logic All other specifications are to remain the same Preserve existing package Requirements Input Power 115VAC, 50/60Hz Control Signals 24 VAC Inputs Outputs +20 to +65 Degrees Celsius Humidity 0 to +40 Degrees Celsius Storage Temperature NEMA-12 Wall Mountable w/Quick Release Door Latch (10’’ x 6’’ x 4’’) Operating Temperature Unit 1: Air Conditioning 1, Heat 1 Unit 2: Air Conditioning 2, Heat 2 Enclosure Thermostat 1: Air Conditioning 1, Heat 1 Thermostat 2: Air Conditioning 2, Heat 2 Below 90% Atmosphere Free of Corrosive Gas and Dust Approach Extract existing design from previous group’s documentation and new hardware Replace FPGA development kit with microcontroller Develop PCB design partitioning circuit components Fabricate assemble and test design System Diagram PGC Vpp PGD PicKit 2 Programmer 120V AC AC Neutral System Gnd Chassis Gnd Power Conversion 5V Gnd PGC Vpp 120V AC Power Supply PGD Programming Header Vpp PGD PGC Vcc Gnd RB0 Heat Signal Gnd A\C Signal Gnd ON\OFF HVAC 1 Output Relays RB1 Heat Heat Signal Gnd A\C Signal Gnd ON\OFF ON/OFF Signal Gnd HVAC 2 Thermostat 1 A/C ON/OFF Demand 1 Signal Gnd Signal Conversion Heat ON/OFF Demand 1 RxD RD0 Controller TxD RD1 Signal Gnd Thermostat 2 A/C RxD RS232 Conversion TxD RxD Signal Gnd RA0 RA1 RA2 RA3 RA4 RA0 RA1 RA2 RA3 RA4 RD2 RD3 RD2 RD3 Ribbon Cable ON/OFF Signal Gnd Vcc Gnd Main Board Computer TxD D0 D1 D2 D3 D4 LEDs (5) D0 D1 Control Buttons (2) Vcc Gnd Display Board 120V AC AC Neutral System Gnd Chassis Gnd +5V Power Conversion Gnd +18V To Rest of Board From Wall Socket Power Conversion Diagram Power Conversion Schematic Power Conversion Requirements Provides conditioned power to Signal Conversion Board Inputs 115 VAC IN Outputs +18 VDC (nominal) OUT +5 VDC OUT Signal Conversion Diagram Gnd +5V +18V From Power Conversion To Thermostat 1 Demand 1 Signal Gnd Demand 1 ON/OFF To Microcontroller ON/OFF Signal Gnd Signal Conversion Signal Gnd ON/OFF Signal Gnd Heat Signal Gnd A\C Signal Gnd To HVAC Units ON/OFF Heat Signal Gnd A\C Signal Gnd Signal Conversion Schematic Signal Conversion Functional Requirements Inputs Thermostats provide 24 VAC upon Demand Outputs 2 Heat Inputs 2 Cool Inputs Replaces thermostats to HVAC units 24 VAC sent to HVAC units via relays based on decisions made by microcontroller, I/O Board, or user interface Optical Isolation Optocouplers isolate and protect microcontroller & I/O Board from outside 24 VAC circuitry Signal Conversion 24 VAC Input from Thermostats If +5 VDC from microcontroller Amplified via Darlington array to turn off relay If 0 VDC from microcontroller Conditioned and rectified Electrically Isolated Sent to microcontroller & I/O Board Grounds output of Darlington array to turn on relay 24 VAC Output to HVAC Sent via closed relay Microcontroller Selection Name Cyclone 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 microcontrollers class at Vanderbilt Microcontroller currently used in Bonitron Board Lowest Cost to Project Microcontroller Selection Cyclone II FPGA High recurring and non recurring costs Surface mount with 600+ pins HCS12 Surface mount High non recurring costs 87C51 Third party programming software No C++ support Microcontroller Gnd Demand 1 Demand 1 PGC PGD Vpp PGD PGC Vcc Gnd RB0 ON\OFF RB1 ON\OFF RxD RD0 Controller TxD TxD RA0 RA1 RA2 RA3 RA4 RA0 RA1 RA2 RA3 RA4 To LEDs (I/O Board) RD2 RD3 RD2 RD3 From Buttons (I/O Board) RD1 RxD To Computer (DB-9) From Thermostats (Signal Processing) 5V To Relays (Signal Processing) From Power Conversion Vpp From Programming Header Development Approach Programmable microcontroller Internal UART Internal timer Internal oscillator Compatible with original microcontroller (40 pin DIP) Use PICkit 2 programmer and development kit to code microcontroller Development Methodology User will write the application program in C or assembly code On-board storage RAM Configuration retained as long as the power is on Flash Store program code in non volatile memory MPLAB IDE Development Software Software provided by Microchip for programming PIC microcontrollers Procedure: Write code in assembly language Program microcontroller Test functionality Apply test inputs and observe outputs Design test strategy for all possible cases MPLAB IDE Screenshot PICkit 2 Hardware programmer for PIC microcontrollers USB programmable Connects via 6 pin header on PCB Packaged with starter kit for testing Existing Logic Diagram RS-232 Graphical user interface for control of overrides and timers Parallels functionality of previous override design Replaces variable resistors with programmable timing capabilities Allows user to program timers without physically manipulating the components Programming RS-232 GUI done using Visual Basic Use feedback loop to perform original testing RS-232 Hardware Max 232 transceiver to perform voltage conversion between circuitry and DB-9 Changes voltage range from 0 - 5 VDC to ±15 VDC Floorplan PCB Design Copied 90% from previous PCB layout Added connections for new microcontroller and serial port components 2-sided through hole design allows easier trace routing than previous single sided board PCB Software Developed PCB design using PCBExpress No License required Order directly though the site Extensive parts library Ability to design custom component based on datasheet specification Bottom Side Top Side PCB Design Approval In order to proceed, we request your approval of the design Comments? Near Term Plan Hardware Development Add breakpoints to existing PCB design Obtain parts from Bonitron storeroom Order PCB Test circuit partitions Assemble Test Final product Near Term Plan Software Development Develop assembly language code Refine Visual Basic GUI Hardware Schedule Obtain all components by February 15th Order PCB by February 15th Have assembled prototype boards by March 1st Have full board assembled by March 14th Test till design day Software Schedule Complete GUI by February 22nd Complete programming of the test board microcontroller by March 1st Complete programming of product ready prototype board microcontroller by March 14th System debug and operational testing from March 14 until design day Our webpage: http://eecs.vanderbilt.edu/courses/eece295/2007-2008/Bonitron-HVAC