CAI Networks WebControl PLC User Manual

TM

WebControl

Programmable Logic

Controller

User Guide

Version: 3.2.17f

Hardware Version: 2.2.2

Firmware Version: 3.02.17f5

Firmware datastamp: 10/15/2013

Doc last modified: 11/1/2013

WebControlTM PLC User Guide Version 3.02.17f

Table of Contents

1 Introduction .......................................................................................................... 1

1.1 Scope ............................................................................................................ 1

1.2 Table of Definitions ....................................................................................... 1

2 WebControl

2.1 Power Supply Inputs ..................................................................................... 2

2.2 TTL Output Port ............................................................................................ 2

2.3 AUX Input Port .............................................................................................. 3

2.4 1-Wire Sensor Input ...................................................................................... 3

2.5 Humidity Sensor Input .................................................................................. 3

3 WebControl

3.1 Network Settings ........................................................................................... 5

3.2 Access Settings ............................................................................................ 6

3.3 I/O Setup ....................................................................................................... 8

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I/O ................................................................................................. 2

TM

PLC Web GUI Configuration ........................................................ 5

3.4 X10 RF Control ........................................................................................... 10

3.5 Output Control ............................................................................................ 11

3.6 Notification Setup ........................................................................................ 12

3.7 General Setup ............................................................................................. 15

3.8 Reset Setup ................................................................................................ 16

4 AUX System Inputs ............................................................................................ 17

4.1 Digital Inputs ............................................................................................... 17

4.2 Analog Inputs .............................................................................................. 18

4.3 DS1822/DS18B20 1 Wire Temperature Sensors ....................................... 18

4.4 Honeywell 4000 Series Relative Humidity Sensor ...................................... 19

4.5 Timers ......................................................................................................... 19

4.6 Direct Query System Inputs and Outputs ................................................... 20

5 Real Time Clock ................................................................................................. 21

5.1 Network Requirements to Use the NTP ...................................................... 21

5.2 Realtime Clock Use DS2417 ...................................................................... 21

6 WebControl

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PLC Programming ...................................................................... 22

6.1 The Basics of PLC Programming ............................................................... 22

6.2 WebControl

6.3 WebControl

6.4 WebControl

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PLC Instructions .................................................................. 23

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PLC I/O Identifiers .............................................................. 27

PLC Examples ........................................................................ 30

6.4.1 Example 1 Set Output based on condition .......................................... 30

6.4.2 Example 2: Flash TTL output ............................................................. 31

WebControlTM PLC User Guide Version 3.02.17f

6.4.3 Example 3: Push Button Input Control Output ..................................... 32

6.4.4 Example 4: Send EMAIL ..................................................................... 32

6.4.5 Example 5, Parallel I/O ........................................................................ 33

6.4.6 Example 6, Sequential I/O ................................................................... 34

6.4.7 Example 7, Traffic Lights ..................................................................... 35

6.4.8 Example 8, Time based Control .......................................................... 36

6.4.9 Example 9, Battery Charger ................................................................ 39

6.4.10 Example 10, RFID reader and browser Control .................................. 40

6.4.11 Example 11, Bitwise Operation ........................................................... 41

6.4.12 Example 12, Angle Calculation ............................................................ 41

6.4.13 Example 13, Non-Blocking Delay ........................................................ 42

6.4.14 Example 14, Your Examples ............................................................... 42

7 WebControl

TM

PLC FAQ .................................................................................... 45

7.1 Login and Configuration .............................................................................. 45

7.2 Temperature Sensor Support ..................................................................... 45

7.3 Turn on/off TTL output from another programming language ..................... 46

7.4 External Analog Chip DS2450 .................................................................... 47

7.5 Power Supply Requirement ........................................................................ 47

WebControlTM PLC User Guide Version 3.02.17f

Table of Figures

Figure 1.0 WebControlTM PCB inputs and outputs diagram ........................................ 2

Figure 2.0 WebControl

Figure 3.0 WebControl

Figure 4.0 WebControl

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sensor connections ............................................................. 3

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PLC system status .............................................................. 5

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PLC Network configurable .................................................. 6

Figure 5.0 I/O setup .................................................................................................... 8

Figure 6.0 WebControl

Figure 7.0 WebControl

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X10RF Control .................................................................. 10

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Output Control .................................................................. 11

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email setup ....................................................................... 13

Figure 8.0 Network defaults ...................................................................................... 15

Figure 9.0 WebControl

Figure 10.0 WebControl

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J12 Input pins ................................................................... 17

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Temperature sensor assignments .................................. 18

Figure 11.0 DS2417 layout ....................................................................................... 21

WebControlTM PLC User Guide Version 3.02.17f

1 Introduction

This document provides an overview of the technical aspects of using WebControlTM

PLC. It describes the inputs and outputs offered by the PLC version of the

WebControl

found in chapter 6 of this document. Function, usage and syntax as well as many

examples are provided there to help you get started. WebControl

from the earlier WebControl

flexibility in I/O control; but in return, expects user to learn programming concepts

and write an assembly like PLC program. A PLC program has the ability to read

write and compare values of the available inputs, outputs, variables and timers. With

a PLC program loaded and running, WebControl

without a network connection. The PLC programming module and programming

guide are provided for a learn-on-your own experience. Assistance in writing or

debugging PLC code is not provided as part of the regular technical support for

WebControl

TM

hardware and firmware. The WebControl PLC Programming Guide is

TM

PLC is different

TM

BRE. The PLC version of firmware provides greater

TM

PLC can operate on its own,

TM

PLC configuration.

1.1 Scope

The scope of this document is to be a guide for configuring and using the features

provided by WebControl

TM

. The reader is expected to be technically competent in all

the technical areas within this document, and is strongly advised to use this

document alongside the other reference material listed in the reference section.

1.2 Table of Definitions

The following table is a list of definitions used though out the document.

Definition

HTTP Hypertext transfer protocol DNS Domain name server SMTP Simple mail transport protocol SNTP Simple network time protocol 1-wire Special bidirectional serial data bus from Maxim RH Relative humidity NetBios Human readable name used as an alternative to an IP address for

IP Internet protocol DHCP Dynamic host configuration protocol ROM Read only memory PLC Programmable Logic Controller

Description

accessing the server on a network. E.g. http://WebControlTM

WebControlTM PLC User Guide Version 3.02.17f

2 WebControlTM I/O

The current hardware version of WebControlTM is equipped with a number of inputs and outputs; these are shown in below in figure 1.0.

Figure 1.0 WebControl

TM

PCB inputs and outputs diagram

2.1 Power Supply Inputs

The DC power supply input is the electrical supply to the board. The recommended input voltage is 9V DC. Any voltage greater than 12V applied to this input may require adding heatsink to regulator, otherwise it may overheat.

2.2 TTL Output Port

The TTL logic level output port has 8 TTL outputs that can each be set or cleared using web GUI command codes, or by setting up a PLC using the available inputs, variables, and timers, so that the particular output is set when a particular condition is met. The maximum current that can be sourced or sinked by one of these outputs at a time is 20mA or 100mA for the whole board. TTL 0 level defined as 0-2V and TTL 1 level is define 3-5V with TTL 0 almost 0V and TTL 1 almost 5V depending on the

WebControlTM PLC User Guide Version 3.02.17f

load. TTL output current is capable to drive standard solid state relay, but will not be able to drive those coil based relays. Be aware of the current requirements of the circuits/loads attached to these outputs. Damage will occur to the board if too much current is allowed.

2.3 AUX Input Port

The AUX input connector offers digital and analog inputs that can be monitored or programmed to set a single TTL output or several TTL outputs. Three analog inputs are available, each have an input range of 0 to 10Vdc. Eight digital inputs are available and use TTL input levels (labeled as J12AUX in Figure 1) shows the layout of this port in more detail. The

matching connector for this port is TYCO ELECTRONICS - 1658622-3 .

(0 and 5Vdc). The AUX Input Port pin out diagram

2.4 1-Wire Sensor Input

The 1-wire sensor port allows up to eight Maxim DS1822/DS18B20/DS18S20 1-wire temperature sensors to be connected. It also allows one Maxim DS2417 real time clock, and one DS2450 4 channel A/D converter. The temperature and analog input can be displayed via the HTTP browser and can be used as inputs to the PLC engine to control the TTL output port. Since hardware revision 2.2.2 uses 5V to power 1wire bus, there is no need for any external power to the sensors. Please note if more than one DS2450 is attached to 1-wire bus, only the first one will be used by the firmware. If more than 10 1-wire devices attached to the bus, only the first 10 will be used.

2.5 Humidity Sensor Input

The current WebControlTM hardware has been designed to use the Honeywell 4000 series relative humidity sensor devices. Using any other humidity sensor without careful consideration may result in malfunction of this feature. The RH sensor can be used to display relative humidity via HTTP or be used to control the TTL outputs as an input in the PLC engine.

Figure 2.0 WebControl

connections

Please make sure the temp sensor and humidity sensor connected similar to this picture. Reverse the polarity may cause damage to the board.

TM

sensor

WebControlTM PLC User Guide Version 3.02.17f

3 WebControlTM PLC Web GUI Configuration

To access WebControlTM PLC, connect WebControl

TM

to the local network and power

supply. The default IP address will be 192.168.1.15. Be aware that once you enable

DHCP in your WebControl network settings page, you will need to check your DHCP

server log for which IP address DHCP assigned to the board. You need to know and

understand the network you attaching this hardware to in order to know where to look

for DHCP server logs. For home networks, DHCP serving is commonly enabled at

the router. Each WebControl

TM

PLC board has a unique MAC address. Look in the

DHCP log to find the matching MAC address, then you can find the IP address

DHCP assigned to the hardware. From a computer connected to the same network,

start a web browser, and point to that IP address: for example: http://ww.xx.yy.zz

when the web page loads, you will be prompt for login. The default user ID and

password is: “admin/password”, all in lower case. You will see this page once

logged in:

Figure 3.0 WebControl

TM

PLC system status

3.1 Network Settings

These are the basic settings that need to be configured in order for WebControlTM to

work successfully on a network. It may be necessary to connect the board directly to

a PC and access it using its default IP address before connecting directly to a live

WebControlTM PLC User Guide Version 3.02.17f

network in order to configure it correctly. Figure 4.0 shows the Network settings

WebControl

TM

has.

Figure 4.0 WebControl

TM

PLC Network configurable

3.1.1 NTP Server Settings

This version changed from previous versions by reduced Allowed Limits host IP

address from eight to four. In addition, it added NTP Server section to allow user to

enter his local NTP server’s IP address to overwrite the default pool.ntp.org resolved

IP address. By default NTP server field should be 0.0.0.0, so that WebControl

TM

will

use pool.ntp.org as the Network Time Protocol server.

3.1.2 Access Settings

For security purpose, you can decide your own user name and password. For being

used over Internet, you may also set the access list, so that only host in the list can

WebControlTM PLC User Guide Version 3.02.17f

access the WebControlTM board over the network. Please note that if any entry is

0.0.0.0, all IP addresses can access it.

WebControlTM PLC User Guide Version 3.02.17f

3.2 I/O Setup

WebControlTM PLC allows users to directly from browser control each output, or

through the PLC logic to control the TTL output. For flexibility, user can decide if the

TTL input or out to be inverted between logic 0 and logic 1. To use PLC logic, first

user must check the “Global PLC enable” to start the PLC engine. Then for each

TTL output, user can decide if the PLC control will be applicable.

Figure 5.0 I/O setup

WebControl

TM

PLC allows user using browser to directly control the output state. If a

command line utility or third party control software used, you will need to enable the

Browser Control for that TTL output, also may need to go to network configuration to

disable the Web login (see figure 4.0).

The inverted state will be remembered in EEPROM even after power loss. The invert

state will be restored upon power resumed.

X10 Enable will allow user to send X10RF commands through TTL port7 and TTL

port8. Those two ports will not be able to perform any other function, once X10 is

enabled.

WebControlTM PLC User Guide Version 3.02.17f

Counter Enable /Frequency Measurement Enable/TTL Input Enable are radio buttons

that you can only select one of them. Those functions sharing the same TTL1 input.

Please note the Counter is triggered at rising edge after the falling edge. If your

counting source TTL level was zero from start with, you may miss count by 1.

Frequency measurement is up to 2MHz.

WebControlTM PLC User Guide Version 3.02.17f

3.3 X10 RF Control

Figure 6.0 WebControl

TM

X10RF Control

WebControl uses TTL7 and TTL8 to control X10RF devices. User must already

enabled X10RF function in the I/O Setup screen. An external RF transmitter must be

attached to the output port TTL7, TTL8, and ground. In the USA, the X10 RF

frequency is 310MHz, and in Europe, the frequency is 433 MHz WebControl can

send all 16 house codes and 16 unit codes, controlling total 256 devices.

X10 RF function is supported in the PLC programming also.

In PLC programming, PLC command is in the format:

X10 H U C

Where H is house code from 0-15, U is unit code, also from 0-15; C is one of

following four commands: 0 – Off, 1 – On, 2 – Bright, 3 – Dim. H,U,C can be

variables so that user can dynamically change the X10 operation in PLC logic.

If the X10 function enabled, TTL7 and TTL8 should not be used for controlling other

devices. Please note PLC logic uses 0-15 or 0-0xF for code, web GUI only use 0-F.

WebControlTM PLC User Guide Version 3.02.17f

3.4 Output Control

Figure 6.0 WebControl

TM

Output Control

When click on each TTL output On or Off, the current state of the TTL output will

change. However, the display may or may not update depending on the “Web

pulling” enabled in the General Setup screen. If you did not enable the “Web Pulling”

to save the bandwidth, you will need to use browser refresh to see the output state

change. Please note “Save States” button will make WebControl store the state in

the EEPROM. When power lost and reapplied, the output will remember the states

being saved.

WebControlTM PLC User Guide Version 3.02.17f

3.5 Notification Setup

WebControlTM allows up to 8 different email notifications to be send from the PLC

program. Please note the port can be any number, but WebControl current hardware

cannot support SSL enabled email. Certain email servers like Gmail requires use

SSL enabled email client. WebControl does not support that. However, WebControl

does allow sending email out from port other than 25. Most local ISP provides the

non-SSL email server on port other than 25, for example, Yahoo email using port

587. Please contact your local ISP first to find out how to sending out non-SSL

encrypted email. For example, Yahoo email can be used:

SMTP Host = smtp.mail.yahoo.com Port 587

username = your-Yahoo-email-account,

password = your password used

From field = Your Yahoo mail

From firmware 3.02.16, user can specify different email address for different email

notification. So that different email can be send to different person for a different

event.

WebControl 3.02.16 firmware also allow HTTP GET to be used to set the VAR or

output state to another WebControl board, provided the other board does not enable

logic. If the security is concern, please set up allowed host in Network Setup screen.

This HTTP GET feature can also be used to send notification to the remote HTTP

server, given the remote server does have CGI logic to process the HTTP GET sent

from WebControl. User can specify up to 8 different URLs on each board. There are

three fields in each URL. The first field is IP address and port, in the format of

192.168.2.15:81 . The “:” is to separate the IP address and remote HTTP port. There

is no space. It is followed by virtual host name. The URI portion of the URL is a

string leading all the way to the value being set on the WebControl or remote HTTP

server. The last part of the URL is the Base64 encrypted use name and password.

This will allow one WebControl to set value in another WebControl with password

protected. If the other side does not require login, this field can be left blank.

For example, if you want to set a remote WebControl board VAR1 to value 1234, you

simple in the PLC logic calling:

WEBSET URL1 1234

Or

WebControlTM PLC User Guide Version 3.02.17f

WEBSET URL2 VAR1

Please note WEBSET has sending queue of four. If there are WEBSET requests

coming more than the queue can hold, the older requests will get lost. In addition, if

the remote WebControl or server does not respond, the WEBSET will fail.

Figure 7.0 WebControl

TM

email setup

Starting from the 3.2.15 firmware, we allow user to configure less I/O being report. By

default, all I/O status is reported in the email.

Please note that although there are 8 EMx and 8 URLy, WebControl internally only

has queue for up to five emails and eight URLs queued for sending. If PLC logic

made such a call too fast, the newer email or WEBSET notification will overwrite the

older ones in the queue.

WebControlTM PLC User Guide Version 3.02.17f

Most email notification problems are either the configuration problem or the SMTP

host rejected email. In this version PLC firmware, user can send a test email to see if

the email notification working or not. In earlier version user guide, it was not clearly

stated the email message ID is in format of EM1 through EM8. Using number only or

other string may send out wrong email message.

WEBSET feature allows setting VAR value in another WebControl board, or setting

value on your web server, if you have proper CGI code developed to take. For

example, to set a value in ISY from Universal Devices, you can configure the URL1

to:

IP_address:port:virtual_host for example: 192.168.2.222:80:www.mydomain.com

Please note ISY99 using port 80

URI example: /rest/vars/set/1/15/

Base64 encrypted username:password: Example: YWRtaW46cGFzc3dvcmQg

Between username : and password, there is no space. In earlier version, you need to

specify “

encrypted user ID and password, so that “

AUTHBASIC:” from 3.02.17 firmware, the third field is dedicate for the

AUTHBASIC:” can be omitted.

In your PLC logic, you can put this command:

WEBSET URL1 VAR1

Then it will set ISY variable 15 to the value of VAR1.

To do base64 encryption, you can go to our web site at:

http://www.cainetworks.com/support/base64-encoding.html

From 3.02.17 firmware, server CGI code can return a 32bit signed number to

WebControl during WEBSET call. Please refer to the chapter 6 example 15 for how

to write the CGI code and how to refer to this returned value.

To obtain support for email or WEBSET feature, full TCP capture data is required.

The captured data must be able to fully display in WireShark software.

WebControlTM PLC User Guide Version 3.02.17f

3.6 General Setup

When WebControlTM is connected to the network it will obtain NTP time from Internet.

User need to set correct time zone on WebControl

TM

PLC.

Figure 8.0 Network defaults

If the WebControl cannot reach to pool.ntp.org over Internet, it will use its own built-in

clock with less accuracy. If a DS2417 real time clock chip connected to 1-wire bus,

WebControl will query it for the time. User may change and update the clock from

this screen by typing MM/DD/YY HH:MM:SS format in the Set Date Time input field,

then click “Send” button. If a DS2417 chip is discovered on 1-wire bus, the real time

clock will be set to this time. When synced with NTP server, real time clock chip

DS2417 is also set every 10 minutes.

UROM1…UROM4 are four identifiers can be used in PLC program. They can help

user to fine tune their PLC program for different setup. These four values are stored

in the EEPROM, so that when power lost, its value will be kept by the EEPROM.

When power restored, UROM value will remain whatever they set before. There are

two ways to set UROM value. One is to set it on this web GUI page by save modified

WebControlTM PLC User Guide Version 3.02.17f

value. Another way to set their value is to use /api/seturom.cgi call. Please refer to

the FAQ section for that method.

For 1-wire devices on a complex bus configuration, its timing is critical. Time Data

Sample Offset (TDSO) field is for user making his own timing adjustment based on

his setup. Default TDSO is 15uS. For shorter bus, it can be reduced to 14uS or

lower. For longer bus, 16uS or longer may be desirable. 1-wire signals are travelled

in CAT5 cable at speed about 20Meter/uS. However, we recommend to add filter

resistor to reduce bounced signals from stub wire and far end of the bus, instead of

change the timing.

When Web polling enabled, WebControl

TM

PLC building active Java code will

constantly update the browser display for temperature, humidity, and I/O status.

Please note with such a update, it may take significant amount bandwidth from your

network, as well as WebControl’s processor power.

3.7 Reset Setup

If the configuration was totally mess up, user can reset the board to factory default

configuration by shorting the RESET jumper while powering up the WebControl

Please note reset will wipe out the entire configuration, including the PLC program.

Please make sure backup your PLC program before reset. After reset, the login ID

and password will be restored to “admin/password”. Default IP address is

192.168.1.15 with DHCP disabled.

TM

.

WebControlTM PLC User Guide Version 3.02.17f

4 AUX System Inputs

The system AUX inputs of WebControlTM are used as inputs to the PLC engine (see

section 5.1). This section describes the connector ladled as J12. Digital and analog

inputs come through J12 connector.

Figure 9.0 WebControl

TM

J12 Input pins

4.1 Digital Inputs

WebControlTM has eight digital TTL inputs, each of which can be configured to be

inverted upon input to the system. The PLC engine will then look for a true of false

case of the input. TTL level 0 is defined 0-1.75V; TTL level 1 is defined as 3-5V.

When TTL1 being used as counter/frequency measurement purpose, its counts

pulses up to 2MHz and max count is 32bit number. Counter starts counts from rising

edge after the falling edge.

WebControlTM PLC User Guide Version 3.02.17f

4.2 Analog Inputs

WebControlTM has three built-in analog inputs each having an input voltage range of

0 to +10V. When a DS2450 chip is connected to the 1-wire bus, additional analog

input AIP5,6,7, and 8 are displayed. DS2450 chip has 10 bit resolution and full scale

voltage is 0 to +5.0V. Both built-in and optional DS2450 A/D inputs have the full

scale range of 0 – 1023. To reduce A/D noise, user may add a 470uF 6.3V capacitor

crossing 5V and ground terminal on the J12 header or temperature sensor terminal.

In PLC code, user can reference to the fourth analog input value AIP4, which is the

reading from humidity sensor.

4.3 DS1822/DS18B20 1 Wire Temperature Sensors

WebControlTM supports up to eight Maxim DS1822 /DS18B20 12bit 1 wire

temperature sensors. Each temperature sensor must be first assigned a temp sensor

number T1-T8.

Figure 10.0 WebControl

TM

Temperature sensor assignments

Each temp sensor has unique ROM code. One temp sensor can be assigned for

different sensor number. User can also select the unit as Centigrade or Fahrenheit. If

sensor failed later due to sensor failure or wire problem, WebControl

TM

will display

the state as failed, but keep the last valid sensor value. This is to prevent the PLC

logic turn on heater/cooler or motor undesirably.

WebControlTM PLC User Guide Version 3.02.17f

4.4 Honeywell 4000 Series Relative Humidity Sensor

The WebControlTM hardware is designed to support one Honeywell 4000 series

relative humidity sensor. The Honeywell sensor output is ‘almost’ linear voltage

between 0 - +5V dc proportional to the relative humidity. This output is fed into one of

the A/D converter channels on the microcontroller. CGI command codes are

available to setup an upper and lower threshold for the humidity sensor that can then

be used in the Boolean expressions.

WebControl PLC has calibrated the humidity curve at 11%, 25%, 45%, and 78%.

However, due to sensor differences, some sensors may read the humidity value

different from actual value. Adding a 5K linear potentiometer (pot) in series with pin 3

(5V supply line) can help user to adjust your sensor match the accurate humidity

reading. If the humidity reading varies a lot, which is an indication your power supply

is not providing enough voltage to the board.

4.5 Timers

WebControlTM PLC is different from BRE engine. User must write PLC code to

implement timers and delay functions. There is no hard limit of number of timers and

delays, There are blocking DELAY and non-blocking delay functions detailed in

section 6.2. WebControl PLC has built-in timer reference value for PLC coding:

 CD Current date mm/dd/yyyy format  CT Current time hh:mm:ss format  CDW Current day of week  CH Current hour of day  CM Current minute of hour  CS Current second of minute  CDAY Current day of month  CMONTH Current month of year  CYEAR Current year  CTS Current Total Seconds from 1/1/2000

WebControl timer variables are in one mili-second minimum resolution. However,

due to high priority I/O like handling, like 1-wire interrupt, the accuracy of the timer

may in the range greater than 10mS. For how to program the timer functions, please

read Chapter 6 completely. There are a few examples described how to program the

WebControl PLC to act based on the input conditions and timer conditions.

WebControlTM PLC User Guide Version 3.02.17f

4.6 Direct Query System Inputs and Outputs

To integrate with other servers, directly query I/O status maybe desirable. Using wget

command from other servers or computers, user can directly query each input and

output status. The following HTTP commands are directly return the I/O values:

“geta1.cgi, geta2.cgi, geta3.cgi” – to query analog input values

“geth1.cgi” – to query the humidity sensor readings

“geti1.cgi, geti2.cgi,..geti8.cgi” – to query each digital input values

“geto1.cgi, geto2.cgi,...geto8.cgi” – to query each TTL output status

“gett1.cgi, gett2.cgi,...gett8.cgi” – to query each temperature sensor value

“getts1.cgi, getts2.cgi,...getts8.cgi” – to query each temperature sensor status

“getcounter.cgi” – to query the counter value

“getfcounter.cgi” – to query the frequency measurement per second value.

“getall.cgi” – to query all sensor and I/O status

VAR1-VAR8 can also be set by web UI. Please see FAQ section for how to do that.

WebControlTM PLC User Guide Version 3.02.17f

5 Real Time Clock

WebControlTM has a build-in clock functions that doing time keeping by using an

atomic clock via the simple network timer protocol (SNTP). Configuration is required

TM

to set the correct time zone of the clock. When NTP is not available, WebControl

will use its own crystal to maintain the clock accuracy. If NTP is available, only need

to set the time zone in the clock page. If NTP is not available, please set your local

clock in the clock page also. Without NTP, its internal clock may not as accurate.

Firmware 3.2.9 and later supports DS2417 real time clock IC. Please reference to

Maxim-IC web site for DS2417 and its PCB layout recommendation. To build an

accurate real time clock, the crystal with exactly the part number listed in the Maxim-

IC document is critical.

WebControl will check if a DS2417 existence during power up. Once it finds the DS2417, it will get its clock synced with DS2417 every 10 minutes. User can update the clock in DS2417 by manually go to “General Setup” screen, put the date and time in that field. The DS2417 will get its clock synced up from that. Or, if NTP is working, WebControl will update DS2417 internal clock every 10 minutes.

5.1 Network Requirements to Use the NTP

WebControlTM must be connected to a network that has access to a DNS server. The

primary and secondary DNS server addresses of WebControl

configured correctly. WebControl

TM

will use DNS to resolve the name of the

TM

are required to be

timeserver. The NTP server WebControl accessing is pool.ntp.org. If internal NTP

server must be used, DNS server must resolve the name record for pool.ntp.org to

your local NTP server’s IP address.

5.2 Realtime Clock Use DS2417

WebControlTM with firmware 3.2.9 supports DS2417 real-time clock. DS2417 takes

one 32.768 kHz crystal, EPSON part number C-002RX or C-004R (make sure load

capacitance is 6pF). One can easily solder the parts similar to this PCB layout:

Figure 11.0 DS2417 layout

WebControlTM PLC User Guide Version 3.02.17f

6 WebControlTM PLC Programming

The WebControlTM PLC firmware can be programmed to execute programmable logic sequences, including comparison and sub routines. This is the major change from the BRE(Boolean Run Engine) version firmware. WebControl like PLC language. Its main program starts with “START” and finishes with “END”. The PLC program is pasted into the web GUI. WebControl will automatically store it into its EEPROM so that if recycle power will not lose the program. The limitation of the PLC is 1000 line of code. The support for PLC programming is not included in the

TM

free support for configuration of WebControl

PLC.

6.1 The Basics of PLC Programming

WebControl PLC program is NOT hard! We have included many examples toward the end of this chapter. A PLC program is made up of main routine and optional subroutines.

The main routine is enclosed between mandatory START and END instructions e.g.

TM

PLC uses assembly

START #main instructions go here END

To change the logic flow, GOTO instruction can be used as unconditional jump from one section of logic to another without call stack to return. CALLSUB instruction is for unconditional logic flow that may return to the original call stack. BNZ and BZ are conditional GOTO to branch to different section in logic. CNZ and CZ are conditional CALLSUB instruction allowing returning to call stack address.

Both GOTO and CALLSUB use label to identify where to execute next instruction.

Label can be any string less than 10 characters. Label cannot be identical to any instruction keyword. If sub routines are used then they are coded after the END of the main routine body. Sub routines start at their label and must end with the instruction RET e.g.

TEST_IO_SUB: #instructions here RET

Subroutines can be called from the main program and from within other subroutines.

Note that WebControl PLC has a return program address stack depth of 8 (or call

stack 8).

The program control block has a zero bit that is updated implicitly on TEST instructions. This zero bit is set by any one of these TEST instructions: TSTEQ, TSTNE, TSTGT, TSTLT, TSTGE, TSTLE,

ANDT, ORT, XORT, ANDBT, ORBT,

XORBT, TSTB. Zero bit flag can be accessed by IO name ZBIT. This zero bit can also be used implicitly when using branch and call instructions, like BZ, BNZ, CZ, CNZ. E.g. the following test instruction yields a Boolean result which will implicitly set

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the state of the zero bit. Next a branch instruction is used which branches on the state of the zero bit.

TSTEQ IP1 1 # sets zero bit based on the result of the test instruction BNZ label # branches to label if zero bit is non-zero

Format of instructions:

label: (optional) opcode operands

Labels must be terminated with a colon ':' and can be a maximum of 10 characters.

6.2 WebControlTM PLC Instructions

The following symbols are used in the table below:

d = destination

a,b..c = operands

() = optional, any operand enclosed in parenthesis mean it is an optional operand.

[] = non-blocking delay operator optional to TTL input/output and VARs. 32 bit

unsigned number, represent resolution of 0.001 seconds. When the delay operator is

used on input operands the current value of that input is only used if it has had that

value for greater than the delay period specified between the brackets. When this

operator is used on an output operand the output value is only set for the period

specified in the brackets. All delay periods are specified in milliseconds. Note that

accuracy and timer resolution is approximately 100ms, even though the delay

operator value is in unit of 1mS.

Opcode Operands Description START Start of main program PROTECTED Must be 2nd Opcode in PLC, will not display PLC code. TSTEQ a[] b[] (d[]) Tests if a is equal to b. Boolean result loaded into optional

destination (d). Zero bit updated with result. If test evaluates to false then the next instruction is skipped.

TSTNE a[] b[] (d[]) Tests if a is NOT equal to b. Boolean result loaded into

optional destination (d). Zero bit updated with result. If test evaluates to false then the next instruction is skipped.

TSTGT a[] b[] (d[]) Test if a is greater than b. Boolean result loaded into

optional destination (d). Zero bit updated with result. If test evaluates to false then the next instruction is skipped.

TSTLT a[] b[] (d[]) Tests if a is less than b. Boolean result loaded into optional

destination (d). Zero bit updated with result. If test evaluates to false then the next instruction is skipped.

TSTGE a[] b[] (d[]) Tests if a is greater than OR equal to b. Boolean result

loaded into optional destination (d). Zero bit updated with

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result. If test evaluates to false then the next instruction is skipped.

TSTLE a[] b[] (d[]) Tests if a is less than OR equal to b. Boolean result loaded

into optional destination (d). Zero bit updated with result. If

test evaluates to false then the next instruction is skipped. SET a[] b Sets I/O id a to the value of b. No zero flag update. SETB a[] b[] d[] Read a and set bit b and puts the result into d. GETB a[] b[] d[] Read a bit position b and puts the result into d. CLRB a[] b[] d[] Reads a and clear its bit position b and puts the result into

d. TSTB a[] b[] d[] Reads a and test its position b and puts the result into d.

Zero bit updated with result. ADD a[] b[] d[] Adds a and b and puts the result into d. Zero bit updated

with result. SUB a[] b[] d[] Subtracts b from a and puts the result into d. Zero bit

updated with result. DIV a[] b[] d[] Divides a by b and puts the result into d. Zero bit updated

with result. MOD a[] b[] d[] Divides a by b and puts the residue into d. Zero bit updated

with result. MUL a[] b[] d[] Multiplies a by b and puts the result into d. Zero bit updated

with result. DEC a Decrements a by 1. Zero bit updated. INC a Increments a by 1. Zero bit updated. AND a[] b[] (d[]) Logical AND's a with b and optionally puts Boolean result

into d. Zero bit updated. ANDB a[] b[] (d[]) Bitwise AND's a with b and optionally puts bitwise AND

result into d. Zero bit updated. OR a[] b[] (d[]) Logical OR's a with b and optionally puts Boolean result

into d. Zero bit updated. ORB a[] b[] (d[]) Bitwise OR's a with b and optionally puts bitwise OR result

into d. Zero bit updated. XOR a[] b[] (d[]) Logical XOR's a with b and optionally puts Boolean result

into d. Zero bit updated. XORB a[] b[] (d[]) Bitwise XOR's a with b and optionally puts bitwise result

into d. Zero bit updated. ANDT a[] b[] (d[]) Logical AND's a with b and optionally puts Boolean result

into d. Zero bit updated. Skip next line if zero. ANDBT a[] b[] (d[]) Bitwise AND's a with b and optionally puts bitwise AND

result into d. Zero bit updated. Skip next line if zero. ORT a[] b[] (d[]) Logical OR's a with b and optionally puts Boolean result

into d. Zero bit updated. Skip next line if zero. ORBT a[] b[] (d[]) Bitwise OR's a with b and optionally puts bitwise OR result

into d. Zero bit updated. Skip next line if zero. XORT a[] b[] (d[]) Logical XOR's a with b and optionally puts Boolean result

into d. Zero bit updated. Skip next line if zero. XORBT a[] b[] (d[]) Bitwise XOR's a with b and optionally puts bitwise result

into d. Zero bit updated. Skip next line if zero. BNZ (a) b If the optional a operand is specified it is tested for a non-

zero value. If a is not specified then the zero bit is tested for

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non-zero. If true then program jumps to label specified in

operand b. BZ (a) b Same as BNZ but tests for zero value. CNZ (a) b Same as the branch instruction but calls a subroutine

instead of branching. See section on program address stack. CZ (a) b Same as above but tests for zero result. CALLSUB a Calls subroutine with label a. See section on program

address stack. GOTO a Branches to program address specified by label a. DELAY a Delay instruction, delay specified in 1/1000 seconds. This

delay is blocking delay, so that next PLC instruction will

not execute until delay is over. NOP A no operation instruction. RET A return from subroutine instruction. EMAIL a Sends email, a = message ID to send EM1 - EM8. X10 a b c a: house code 0-15, b: device code 0-15, c: ON, OFF,

BRIGHT, DIM WEBSET a b a: URL1-8, b: number or VAR, RAM or any other readable SIND a b a: degree, b: VAR or RAM to store the result COSD a b a: degree, b: VAR or RAM to store the result TAND a b a: degree, b: VAR or RAM to store the result ROTL a b c a: source register, b: number of bits; c: result register

rotate to the left, overflow bits will be feed into right ROTR a b c a: source register, b: number of bits; c: result register

rotate to the right, overflow bits will be feed to the left SETLED 0|1|2 0 to turn off green LED, 1 to turn on green LED, 2 default

blinking. IPTS a b reading TTL input last state change time tick counts. 2nd

paramter b is which TTL inut, first parameter a has the

value. IPEDGE undefined not implemented yet END End of main program. This instruction will set the program

counter back to zero and the program will start executing

from the beginning.

Operands

An operand can be any of the following:

• a signed 32 bit decimal number. e.g. 100 or 1 or 0 etc.

• a hexadecimal number. e.g. 0xABF.

• a date stamp in the format MM/DD/YYYY e.g 02/10/2010

• a time stamp in the format HH:MM:SS e.g. 20:25:00

• a day of week identifier enclosed in single quotes e.g. 'sun'. Day of week

identifiers are 'sun' 'mon' 'tue' 'wed' 'thu' 'fri' 'sat'

• an I/O identifier that is a place holder for the real I/O value that the PLC

engine will get at runtime. Valid I/O identifiers are explained in next section.

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6.3 WebControl

TM

PLC I/O Identifiers

The following are the valid I/O identifiers

OP1 TTL Outputs 1...8 Valid range 0 - 1

OP2 OP3 OP4 OP5 OP6 OP7 OP8

IP1 TTL Inputs 1...8 Valid range 0 - 1 IP2 When non-blocking delay added to these input, IP3 its value will return TRUE, if input from 0->1 IP4 longer than the delay value. For example, IP5 IP1[1000] will return FALSE, if TTL input 1 from 0 IP6 to 1 last state change shorter than 1000ms. IP7 IP1[1000] return TRUE only when input 1 from 0 to 1 IP8 and stay at logic 1 for longer than 1000ms.

IPINV1 TTL Invert Inputs 1...8 Valid range 0 - 1 IPINV2 This is exactly same TTL input as IP1,..IP8 IPINV3 except is inverted for filter short pulse purpose IPINV4 its usage is like: IPINV1[1000] to filter 1->0 IPINV5 pulse shorter than 1000ms. If 1->0 pulse is shorter than IPINV6 1000ms, it will return false. Only when input state IPINV7 changed from 1 to 0 and stay that level for longer than IPINV8 1000ms, the value will be TRUE.

AIP1 Analog Inputs 1...3 Valid range 0 - 1024 AIP2 AIP1 to AIP3 are built-in A/D converters. AIP3 AIP5 Optional DS2450 provided additional analog inputs. AIP6 Please note when DS2450 over range, its output is zero.

AIP7 When DS2450 disconnected, its value set to 1023 AIP8

T1 Temperature sensor inputs 1...8 Valid range -550 - +1250. T2 Note that temperature values are specifies in 10's of T3 degrees. So to test for 21.6 degrees C you would use the T4 value 216. T5 T6 T7 T8

TS1 Temperature sensor state 1 or 0. TS2 1 == GOOD sensor, 0 == bad sensor TS3 TS4

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TS5 TS6 TS7 TS8

H1 Humidity sensor valid range 0 - 100

EM1 Email identifiers 1...8 EM2 EM3 EM4 EM5 EM6 EM7 EM8

URL1 WEBSET these URLs 1...8 URL2 URL3 URL4 URL5 URL6 URL7 URL8

CD Current date mm/dd/yyyy format CT Current time hh:mm:ss format CDW Current day of week CH Current hour of day CM Current minute of hour CS Current second of minute CDAY Current day of month CMONTH Current month of year CYEAR Current year CTS Current total seconds since 1/1/2000 (based on local clock)

VAR1 32 bit signed integer variables 1...8 VAR2 The value will be displayed in System Status VAR3 Delay operator is valid on these VAR4 It will help debug your program, if you store debug VAR5 value in VARx. VAR6 VAR7 VAR8

RAM1 32 bit signed integer general purpose RAM 1...8. Delay RAM2 operator is not valid on these. Not displayed anywhere RAM3 RAM4 RAM5 RAM6

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RAM7 RAM8

RAM1H 16 bit signed integer general purpose RAM 1...8. Delay RAM2H operator is not valid on these. Not displayed anywhere RAM3H store in the SAME RAM location as RAM1-8 higher 16 bits RAM4H RAM5H RAM6H RAM7H RAM8H

RAM1L 16 bit signed integer general purpose RAM 1...8. Delay RAM2L operator is not valid on these. Not displayed anywhere RAM3L store in the SAME RAM location as RAM1-8, lower 16 bits RAM4L RAM5L RAM6L RAM7L RAM8L

RAM10 8 bit signed integer general purpose RAM 1...8. Delay RAM20 operator is not valid on these. Not displayed anywhere RAM30 store in the SAME RAM location as RAM1-8, byte 0 location RAM40 RAM50 RAM60 RAM70 RAM80

RAM11 8 bit signed integer general purpose RAM 1...8. Delay RAM21 operator is not valid on these. Not displayed anywhere RAM31 store in the SAME RAM location as RAM1-8, byte 1 location RAM41 RAM51 RAM61 RAM71 RAM81

RAM12 8 bit signed integer general purpose RAM 1...8. Delay RAM22 operator is not valid on these. Not displayed anywhere RAM32 store in the SAME RAM location as RAM1-8, byte 2 location RAM42 RAM52 RAM62 RAM72 RAM82

RAM13 8 bit signed integer general purpose RAM 1...8. Delay RAM23 operator is not valid on these. Not displayed anywhere RAM33 store in the SAME RAM location as RAM1-8, byte 3 location RAM43 RAM53

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RAM63 RAM73 RAM83

RAM1B1 1 bit access to purpose RAM 1 only. This only availavble RAM1B2 for RAM1 Delay operator is not valid on these. Not displayed … anywhere， store in the SAME RAM1 location RAM1B32

UROM1 32 bit signed integer user value stored in EEPROM UROM2 read only, value sets through general tab on web GUI. UROM3 UROM4

COUNTER 32 bit counter can be read, compare, or set FCOUNTER read only, frequency per second up to 2MHz.

WSRPLY read and write, automatically set by web server during WEBSET

call when server specified a value like "SET_WC=12345678".

LED read and write, When read 0 means LED is off, 1 means LED is

on, 2 means LED is heart beat. When write, valie is 0,1,or 2.

ALLINS read only, All 8 TTL as a byte. Only in 3.02.17a firmware

ALLOUTS read write, All 8 TTL output as a byte, only in 3.02.17a

firmware.

6.4 WebControl

PLC Examples

For best understanding how PLC logic working, you can try to copy and paste the examples below into your WebControl PLC program screen to check them out. Please note PLC logic will execute from START to END. Then it will continue from START to END, forever repeating. If you last line of PLC code could skip next instruction, like those TST instruction, it might skip your first line when condition met. Please do pay attention to it. If you use CALLSUB to run subroutine, after finishing the subroutine, the logic will return back to where CALLSUB called and continue.

6.4.1 Example 1 Set Output based on condition

Control incubator heater connected to TTL output 1. If temperature T3 is less than 37 degree C turn ON the heater; if T3 is greater or equal to 39 degree C, turn the heater OFF,.

START TSTLE T3 370 OP1 NOP TSTGT T3 389 SET OP1 0

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END

However, this does not work, when temperature reached above 37 degree C, the OP1 turned off, instead of reaching to 39 degree C. The problem is the OP1 can be set to ON or OFF by the “TSLE T3 370 OP1” line alone. To reduce heater relay constantly turning ON and OFF, it is better to have two subroutines to handle the OP1 state.

START TSTLE T3 370 CALLSUB HEAT_ON TSTGT T3 389 CALLSUB HEAT_OFF END

HEAT_ON: SET OP1 1 RET

HEAT_OFF: SET OP1 0 RET

What if the heater relay stuck, or the heater elements burn out? You can add additional function in this PLC program to send you email notice or sound an alarm for such a situation.

6.4.2 Example 2: Flash TTL output

Flashes output 2 at a rate of 1Hz. (Please note OP2[500] has no space in between which delays 500ms). Please note the delay function used in this example, which is non-blocking, that means the PLC logic will immediately execute next TSTEQ instruction until the delay is over.

START

TSTEQ OP2[500] 0 SET OP2 1 TSTEQ OP2[500] 1 SET OP2 0

END

Another way to implement this is:

START

XOR OP2 1 OP2 DELAY 500 END

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6.4.3 Example 3: Push Button Input Control Output

When a push button connected to TTL input 1 being pushed, set the TTL output 3 ON.

START TSTEQ IP1 1 OP3 TSTEQ OP3 1 SET OP3 0 END

Although this example works, it has flaw. Because all the pushbutton switches from market will not have clean instant ON or OFF, they actually produce a bunch of ON and OFF signals when pushed. If you use a scope to watch IP1 input line or OP3 output line, you will see they are many ON and OFF pulses during pushing or releasing the button. The better way to handle the case is like Example 10 later in this manual. However, if TTL OIP1 connected to a clean signal source, this example does work well.

6.4.4 Example 4: Send EMAIL

To send email 1 when T3 – T2 >= 20 degrees you would use:

START SUB T3 T2 RAM1 TSTGE RAM1 200

EMAIL EM1 END

The above rule is a bit too simple because an email will constantly be generated while RAM1 is greater than or equal to 200. (20 degrees in this case) To guard against that the following logic should be considered. This implementation will only send one email when the temperature comparison beyond the range. If you turn on heater or cooler instead of sending email, similar consideration also should be excised:

START SET RAM2 0 LOOP: SUB T3 T2 RAM1 TSTGE RAM1 200 RAM1 GOTO SEND SET RAM2 0 GOTO LOOP END

SEND:

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BNZ RAM2 LOOP SET RAM2 1 EMAIL EM1 GOTO LOOP

Please note in SEND portion of the code, RAM2 is being checked, if it is already 1, it will skip sending email. Only when RAM2 == 0, an email will be send. Only when RAM1 < 200, the LOOP will skip SEND logic and reset RAM2 to 0.

6.4.5 Example 5, Parallel I / O

This simple program performs 4 separate I/O checks and sets OP1 to OP4 states. In this example, we use subroutine feature of the PLC logic. Although in this case, GOTO can do same thing as CALLSUB, CALLSUB can help program more readable. In certain logic, you have to use CALLSUB instead of GOTO, depending on the logic flow. We will explain more when we run into those examples.

The logic in this example follows:

OP1 is set if T3 > 50 OP1 is cleared if T3 < 50 OP2 is set if IP1 == 1 for more than 300ms OP2 is cleared if IP1 == 0 OP3 is set if AIP1 + AIP2 > 1024 OP3 is cleared if IP4 == 1 OP4 is set if OP1 == 1 OP4 is cleared if OP1 == 0

The PLC code written for the above scenarios would be as follows:

START CALLSUB checkOP1 CALLSUB checkOP2 CALLSUB checkOP3 CALLSUB checkOP4 END

checkOP1: TSTGT T3 500 OP1 RET

checkOP2: TSTEQ IP1[300] 1 OP2

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RET

checkOP3: ADD AIP1 AIP2 RAM1 TSTGT RAM1 1024 BNZ l1 TSTEQ IP4 1 BNZ l2 RET

l1:

SET O3 1 RET

l2:

SET O3 0 RET

checkOP4: TSTEQ OP1 1 OP4 RET

Please note in this example, we assume the TTL input, analog input and temperature reading are all perfect, no bouncing up and down. In reality, you have to add consideration to it.

6.4.6 Example 6, Sequential I/O

The following simple program shows how to set-up sequential I/O.

OP1 is set when IP1 rises from 0 to 1 OP4 is cleared when IP1 rises from 0 to 1 OP1 is cleared when O4 == 1 OP2 is set when T3 > 25 AND OP1 == 1 OP2 is cleared when OP1 == 0 EMAIL1 is sent when OP2 is set O4 is set when OP2 == 1 for more than 1 second

The assembly language written for the above scenario would be as follows:

START BNZ IP1 start l1:

TSTEQ IP1 1 BZ l1 SET OP1 1 SET OP4 0

l2:

TSTGT T3 250 RAM1

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AND OP1 RAM1 BZ l2 SET OP2 1 EMAIL EM1

l3:

TSTEQ OP2[1000] 1 BZ l3 SET OP4 1 SET OP1 0 END

Please note in this example, we assume the TTL input, analog input and temperature reading are all perfect, no bouncing up and down. In reality, you have to add consideration to it.

6.4.7 Example 7, Tra ff i c L i ghts

This example will let pedestrian to push a button to change the light on a busy street, so that he can cross the street safely. IP1 hooks up to the pedestrian crossing button. If someone pushed cross button, the street will have amber light on for 10 seconds, then red light to stop all the cars, allowing pedestrian to cross street in next 30 seconds. At the end of 30 seconds, it will flash the amber and red light for 5 seconds. VAR1 in the main program will let the crossing light turn on every 100 seconds, does not matter anybody push the crossing button or not.

OP1 Red + Pedestrian crossing light OP2 Amber OP3 Green IP1 Pedestrian Push Button

START CALLSUB LIGHTS_GO loop: SET VAR1[10000] 1 loop1: TSTEQ IP1 1 BNZ sr BZ VAR1 sr GOTO loop1 sr: CALLSUB STOP GOTO loop END

LIGHTS_ST:

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SET OP1 1 SET OP2 0 SET OP3 0 RET

LIGHTS_GO: SET OP1 0 SET OP2 0 SET OP3 1 RET

LIGHTS_AM: SET OP1 0 SET OP2 1 SET OP3 0 RET

STOP: CALLSUB LIGHTS_AM DELAY 5000 CALLSUB LIGHTS_ST DELAY 60000 CALLSUB LIGHTS_AM SET RAM2 5 flash: XOR OP2 1 OP2 DELAY 500 DEC RAM2 BNZ flash CALLSUB LIGHTS_GO RET

6.4.8 Example 8, Time based Control

WARNING: For time critical application, please make sure to check CYEAR correct

before taking action based on system clock. When WebControl

ROM hard coded time in 2011. If PLC reporting year 2011, the NTP or real time clock

has not sync the local clock yet.

This example will have five subroutines. WebControl

through them. The “HOURLY” routing will compare analog input 1 and analog input 2,

if A1 - A2 > 10, send an email notice 1. You can use similar logic to adjust your solar

TM

PLC will continuously loop

TM

boot up, it will uses

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panel orientation each hour, etc. The “PERIOD” subroutine will turn on night light

hooked up to OP1 after 18:00 hours and turn it off at 5AM. The “DAILY” subroutine

will start the water sprinkler at 6:30AM for four zones. The “MONTHLY” routing will

check the “salt low” sensor AIP3 on the water softener and send email notice 2. The

“YEARLY” routing will ring the New Year’s bell connected to OP6 on each and every

New Year’s Day for the whole day!

START CALLSUB HOURLY CALLSUB PERIOD CALLSUB DAILY CALLSUB MONTHLY CALLSUB YEARLY END

HOURLY: TSTNE RAM1 CH GOTO T1 RET

T1: SET RAM1 CH SUB AIP1 AIP2 RAM2 TSTGT RAM2 10 EMAIL EM1 RET

PERIOD: TSTGE CH 18 RAM2 NOP TSTLE CH 5 RAM3 NOP OR RAM2 RAM3 OP1 RET

DAILY: TSTEQ CH 7 SET RAM5 0 TSTEQ CH 6 BZ NOTYET TSTGT CM 30 CALLSUB WATERING NOTYET: RET

MONTHLY: TSTNE RAM4 CMONTH GOTO T2

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RET

T2: TSTLE CH 8 GOTO 2EARLY SET RAM4 CMONTH TSTLT AIP3 20 EMAIL EM2 2EARLY: RET

YEARLY: TSTEQ CMONTH 1 RAM2 NOP TSTEQ CDAY 1 RAM3 NOP AND RAM2 RAM3 OP6 RET

WATERING: BNZ RAM5 W_DONE ZONE1: SET OP2 1 TSTLE CM 35 GOTO ZONE1 SET OP2 0 ZONE2: SET OP3 1 TSTLE CM 40 GOTO ZONE2 SET OP3 0 ZONE3: SET OP4 1 TSTLE CM 45 GOTO ZONE3 SET OP4 0 ZONE4: SET OP5 1 TSTLE CM 50 GOTO ZONE4 SET OP5 0 SET RAM5 1 W_DONE: RET

Please note in DAILY subroutine, we call another subroutine “watering”. In this place, we have to use subroutine, since we only want to call this routine after 6:30AM. If current minute is not 30, we will skip. Watering will be done before 7AM, so that we clear the flag RAM5 at 7AM. Also, please notice RAM1, RAM4 and RAM5 are holding static value and RAM2 and RAM3 are temporary storage being used by more than one subroutine. You can decide which RAM is for temporary data, which is for static

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value.

In the PERIOD subroutine, we constantly compare the time and set the OP1 ON or OFF. That is okay for solid state relay or other control relay, since the logic level did not change all the time. However, if you are sending a X10 command to turn on and off different lights, you want to make sure the X10 command only issued once, not repeatedly. You may create another subroutine in which set flag only calls X10 1 15 ON only once to turn ON light at house code 2, unit code 16 (please note WebControl’s X10 house code range 0-F, and device code range also 0-F.)

In the MONTHLY routine, we first check the current hour being 8AM then we check the water softener’s salt level. In this way you will not be waked up by email in the midnight.

When program WebControl PLC for time based logic, please make sure the time being used in different part of the program having no conflict between all the subroutines. If you want two things to happen at the same time, you should consider combine them into same routine to handle.

6.4.9 Example 9, Battery Charger

This is a PLC program to charge 3 serially connected NiMH batteries. First, it tries to discharge the batteries individually. If any battery discharged to 1V, it will stop the discharge and start charging. When each cell is being charged to 1.25V, it will stop charging. We assume the A1, A2, and A3 being calibrated to 1V=100. The measurement on the battery 2 is the total voltage of battery 1 and battery 2. And the measurement on battery 3 is the total voltage of all three batteries. This example will individually discharge and charge each battery.

start

set op1 1 set op2 1 set op3 1 set RAM1 0 set RAM2 0 set RAM3 0

loop:

cnz op1 check_b1 cnz op2 check_b2

cnz op3 check_b3 goto loop end check_b1:

BNZ RAM1 c1

tstle AIP1 100 RAM1

bz e1 c1:

tstgt AIP1 125

bnz e1

set op1 0

set op4 1

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e1: ret check_b2:

BNZ RAM2 c2

sub AIP2 AIP1 RAM4

tstle RAM4 100 RAM2

bz e2 c2:

sub AIP2 AIP1 RAM4

tstgt RAM4 125

bnz e2

set OP2 0

set OP5 1 e2: ret check_b3:

BNZ RAM3 c3

sub AIP3 AIP2 RAM4

sub RAM4 AIP1 RAM4

tstle RAM4 100 RAM3

bz e3 c3:

sub AIP3 AIP2 RAM4

sub RAM4 AIP1 RAM4

tstgt RAM4 125

bnz e3

set OP3 0

set OP6 1 e3: ret

6.4.10 Example 1 0, RFID reader and bro wser Contro l

For office door using RFID reader, as well as allowing operator remote browser control, the following program provided the example. RFID reader’s NC (normally connect) output connects to IP1 on WebControl digital input. A 2.2K pull-up resistor also connected between IP1 and 5V. In this way, each time a valid RFID tag sensed, a TTL “1” feeds to WebControl IP1. Remote operator can also open the door by using browser set OUTPUT TTL1 to on. OP1 connects to the door open switch. TESTEQ logic will make sure the OP1 is an 1 second momentary output.

“LIGHTS” subroutine is for light control outside the office door; the light is on at 7PM and off at 5AM.

START CALLSUB LIGHTS TSTEQ RAM1 0 CALLSUB SET_OP1 CALLSUB CHK4LOW TSTEQ OP1[1000] 1

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SET OP1 0 END

CHK4LOW: TSTEQ IP1 0 SET RAM1 0 RET

SET_OP1: TSTEQ IP1 1 RAM1 SET OP1 1 RET

LIGHTS: TSTGE CH 19 RAM2 NOP TSTLE CH 5 RAM3 NOP OR RAM2 RAM3 OP3 RET

In this logic, SET_OP1 must be subroutine, if “TSTEQ RAM1 0” it will call the subroutine SET_OP1, but if RAM1 != 0, then it will skip that call. In this way, we can guarantee OP1 only being turn on once. In the subroutine SET_OP1, it checks if RFID reader did detected valid RDID card present. If so, it will set the flag RAM1 to true, so that not being set over and over again. For gate opening device, this will make sure the gate will not left open all the time.

6.4.11 Exam ple 11, Bitwise Operation

There are ANDB, ORB, and XORB operator operate on the VAR or RAM on the bit basis. This will allow each RAM or VAR to store up to 31 binary states. When VAR1 stores value 12345, and RAM1 stores value 256, after execute ANDB VAR1 RAM1 VAR1 VAR1 stores the value 0

After execute:

ORB VAR1 RAM1 VAR1

VAR1 stores the value 123712

XORB VAR1 RAM1 VAR1

First execution will be 123712, if execute next time, VAR1 will be back to 12345. In another word, XORB can toggle the bit.

6.4.12 Example 12, Angle Calculation

From 3.02.16c firmware, angle calculation is supported. In PLC program, users can:

SIND 91 VAR1

Or

COSD 185 VAR2

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Or

TAND 630 VAR3

The result for SIND and COSD is x1000, because we can only have integer on this processor. The result for TAND is x100.

6.4.13 Example 13, Non-Blocking Delay

Non-blocking delay is expressed in PLC code as [] next to the operators. The number inside [] is micro-seconds. The [] operation can be on both operators during TST operations. Each input and output and VAR associated with a non-blocking delay timer value. That value is set when I/O state is changed or VAR value being modified. If later PLC instruction using non-blocking delay, that timer value will be referenced. If current time is less than stored timer time plus the delay period, the specified operation will not be performed. Reading value with non-blocking delay will return false if timer value is not meet For example,

TSTGT VAR1[1500] IP1[300] RAM2 If any of those delay not reached, its result will be FALSE.

For SET VAR1[15000] IP1 VAR1 will not be set to IP1 value, unless 15000 milliseconds (15seconds) passed.

6.4.14 Example 14, WEBSET to get server reply

From 3.02.16 version firmware, WebControl allows PLC call WEBSET to do HTTP GET call to HTTP servers inside another WebControl or other devices, or Apache or IIS servers. The web server CGI code can process that information. From 3.02.17 version firmware, the web server can also send back to the WebControl a specially formatted string. When WebControl received that string, it will set an internal variable for user PLC code to reference. Following is an example CGI code from apache server that will set the WebControl base on that reply to turn on or off an I/O bit or take any other action.

Because PLC code does not execute WEBSET call immediately, rather WEBSET is on a scheduler called from queue, user can not expect to get server reply immediately after WEBSET call. The good practice would to check if the WSRPLY value is zero, if that is zero, the server reply has not fetched back yet. Server must return a non-zero value back. If WSRPLY is non-zero, user PLC must read it into another variable and set it to zero, so that it can be used for next WEBSET call. In this sense, if PLC logic wants to get multiple values from server reply, it must issue one call at a time to avoid different WEBSET call return value clashing.

WSRPLY in the WebControl. PLC program can

6.4.15 Example 15, Server CGI Handles WEBSET

The code below is for demonstration only, it is written in C on apache server. We do not provide support for writing server CGI code. Please note to get the best result, server CGI code should write back the string as early in the reply as possible. In HTTP server reply processing, server mostly after sending reply will close connection. If the “SET_WC=2147483647” string sending out too late, it could get lost because the connection is closed already. Please test and make sure your server is response fast enough for the WEBSET call.

WebControlTM PLC User Guide Version 3.02.17f

#include <stdio.h>

#include <stdlib.h>

#include <string.h>

int main(void)

{

char *data, *remote_mac, *remote_host;

long m,n;

FILE *fp;

char buffer[18] = "\r\nnew get call\r\n";

printf("%s%c%c\n",

"Content-Type:text/plain;charset=iso-8859-1",13,10);

data = getenv("QUERY_STRING");

remote_mac = getenv("HTTP_USER_AGENT");

remote_host = getenv("REMOTE_ADDR");

fp = fopen("/tmp/webcontrol.txt", "w+");

fwrite(buffer, 1, strlen(buffer), fp);

if(data != NULL) {

fwrite(data, 1, (unsigned int) strlen(data), fp);

fwrite(buffer, 1, strlen(buffer), fp);

}

if(remote_host != NULL) {

fwrite(remote_host, 1, (unsigned int) strlen(remote_host), fp);

fwrite(buffer, 1, strlen(buffer), fp);

}

if(remote_mac != NULL) {

fwrite(remote_mac, 1, (unsigned int) strlen(remote_mac), fp);

fwrite(buffer, 1, strlen(buffer), fp);

} else

fwrite(buffer, 1, strlen(buffer), fp);

/***************************************************

put your logic here if MAC address not match then do what

You can simply return with an error message

****************************************************/

/****************************************************

Now, you can process the data string send in by WebControl

****************************************************/

WebControlTM PLC User Guide Version 3.02.17f

printf("to push up to 10 bytes to WebControl SET_WC=-2147483647\n");

printf("close connection\n");

fclose(fp);

return 0;

}

WebControlTM PLC User Guide Version 3.02.17f

WebControlTM PLC FAQ

We include some users frequently asked questions here:

6.5 Login and Configuration

1-1Q: Can you tell me how to connect with Windows Explore? I cannot communicate? 1-1A: If you have DHCP server on your network, please check with your DHCP server log, WebControl is likely obtained an IP address from your DHCP server. Once your find out the IP address assigned by DHCP server, you can use browser to connect to:

http://what-ever-dhcp-assigned-ip/ You will see the login screen.

If you don′t have DHCP server on your network, WebControl's default IP address is

192.168.1.15. You must change your computer's IP address temporarily to

192.168.1.1, (make sure no other host using that IP address on your network), then from IE browser enter:

http://192.168.1.15/ You will see the login screen.

1-2Q: I have problem to setup the clock, it does not work, even I setup my network and DNS server correctly? 1-2A: Please check with your ISP to make sure the DNS server IP address is valid. If you have Linux computer, you can use dig command to make sure that DNS server IP can resolve the ntp.org. Please note that many ISPs restrict the DNS access from outside its own IP address range. If your DNS server IP is not from your ISP, it may not work.

dig ntp.org @your-dns-server-ip

1-3Q: What is the default user ID and password, can I change it? 1-3A: The default user ID and password is admin/password, all lower case. User can change both user ID and password.

6.6 Temperature Sensor Support

2-1Q: The document stated supporting DS1822/DS1820 1 Wire Temperature

Sensors, I assumed the whole DS18xx family of devices would work. I used a

DS18S20+ and get about 3.5 degrees C when powered, 10.6 when parasitic

powered. It should read 23-24 at room temperature. For power I tried pin 3 of the

temperature terminal and pin 3 of the humidity terminal and the result is the same.

2-1A: WebControl™ can simultaneously connect 8 optional

DS18B20/DS1822/DS18S20 based digital temperature sensors. In the past we

require 12bit temperature sensor. Now, we lose the requirement to 12bit and 9 bit

Maxim-IC temp sensors. We still do not support parasite part.

WebControlTM PLC User Guide Version 3.02.17f

2-2Q: How to read temperature or sensor ROM code from command line in Linux?

2-2A: Use wget http://webcontrol-ip/gett1.cgi to read the temp sensor T1, and use

wget http://webcontrol-ip/gett1rc.cgi to read the sensor T1 ROM code.

2-3Q: What can cause my temperature sensor not display correctly?

2-3A: Use solid copper wire for your 1-wire bus, for example, CAT5 cable. Reduce

any unnecessary length of the wire. Do not hook up unsupported parts to the 1-wire

bus, since they may generate 1-wire signal causing trouble.

2-4Q: I run a long cable between the DS18B20 and WebControl, sensor does not

work?

2-4A: According to Maxim-IC, if using a long cable connecting between the sensor

and host controller, it may require to add a pull-up resistor 4.7k from 1-wire bus (DQ

pin on DS18B20) to the 5V supply near the far end of the 1-wire bus. Please check

out Maxim-IC AppNote148. You do not have to add external power, if you do not

experience any problem.

6.7 Turn on/off TTL output from another programming language

3-1Q: I want to turn on/off TTL output from Visual Basic, can I do it?

3-1A: You can reference how the browser does it and emulate that in your VB or

script. Please make sure to disable login in the "Network Setup" screen. For security

purpose, please specify the IP address in the access list, or your application sending

encrypted user ID/password in the same HTTP call. Depends on the IP address and

which TTL you want to control by programming language, you may refer to these two

browser URL lines:

http://192.168.1.15/api/setttloutput.cgi?output=1&state=1 to turn on,

http://192.168.1.15/api/setttloutput.cgi?output=1&state=0 to turn off.

and to manually set a VAR value from outside, varid from 1 to 8:

http://192.168.1.15/api/setvar.cgi?varid=1&value=23456789

from 3.02.17 firmware, WebControl supports manually set a UROM value from

outside, uromid from 1 to 4:

http://192.168.1.15/api/seturom.cgi?uromid=1&value=23456789

WebControlTM PLC User Guide Version 3.02.17f

Command line browser wget can be used to do manually control. The above lines

maybe need in double quotes to work.

6.8 External Analog Chip DS2450

4-1Q: I have DS2450 on the 1-wire bus, but reading is not stable?

4-1A: Maxim-IC DS2450 known for its sensitivity to noise. Please make sure to add

100pF disc capacitors across the chip on its VDD to ground, and from each analog

input immediately to the ground, also. Any anlog input channel should have 1K input

resistor to block some the incoming noise.

6.9 Power Supp ly Requirement

5-1Q: What kind of power required to run WebControl?

5-1A: WebControl 2.2.2 hardware can operate from 7.5 to 12VDC power supply.

However, when using DC12V, the regulator will be VERY hot. It is recommended to

run on 9VDC1A power supply. Please make sure power supply has good filtering

capacitors. Any noise in the power supply could cause problem during execution of

WebControl PLC logic. If a relay board is also used with WebControl, please make

sure the power supply has enough reverse current to handle the spike during relay

switching.

CAI Networks WebControl PLC User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual