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APN007
User Manual
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CTEK APN007 User Manual

Application Note
Ctek Automation Control Application
APN007
Release 4.02.02
Ctek – Things That Move Data
.
i
Contents
TABLE OF FIGURES.........................................................................................................................................................IV
INTRODUCTION: .............................................................................................................................................................. 1
THEORY OF OPERATION ............................................................................................................................................... 1
NAVIGATION AND TOP LEVEL FUNCTIONS: ........................................................................................................... 2
Automation Control Panel.................................................................................................................................................................2
Automation Control Configuration ....................................................................................................................................................2
USER INTERFACE AND CONFIGURATION SPECIFICS ........................................................................................... 4
Execute New Configuration ...............................................................................................................................................................4
Unit Configuration .............................................................................................................................................................................4
Location Name: ...................................................................................................................................................................................... 5
SMS Remote Control: ............................................................................................................................................................................. 6
Logging On/Off:...................................................................................................................................................................................... 6
Log Rate: ................................................................................................................................................. Error! Bookmark not defined.
Alarms On/Off: ....................................................................................................................................................................................... 6
Alarm Delivery Method: ......................................................................................................................................................................... 6
Destination Phone Number for Alarms:................................................................................................................................................. 6
Destination email address for Alarms: ................................................................................................................................................... 6
Log Delivery Parameters: ...................................................................................................................................................................... 6
Email address for this device: ................................................................................................................................................................ 6
Email User Name and Password ............................................................................................................................................................ 6
SMTP Server Address and Port: ............................................................................................................................................................. 6
Authentication and SSL Encryption:....................................................................................................................................................... 7
Display Group Names:............................................................................................................................................................................7
I/O Modules ......................................................................................................................................................................................7
Add:........................................................................................................................................................................................................ 8
Delete:.................................................................................................................................................................................................... 8
Replace:.................................................................................................................................................................................................. 9
Disable.................................................................................................................................................................................................. 10
Enable .................................................................................................................................................................................................. 10
Configure Outputs ...........................................................................................................................................................................11
Output Configuration Screens ............................................................................................................................................................. 12
Configure Inputs ..............................................................................................................................................................................15
Input Configuration Screens ................................................................................................................................................................ 15
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More About Digital Inputs and Outputs ..........................................................................................................................................24
Understanding The Input and Output Polarity Setting ........................................................................................................................ 24
Min/Max Range and Sensor Calibration: ............................................................................................................................................ 25
Analog Input Processing....................................................................................................................................................................... 26
Thresholds............................................................................................................................................................................................ 26
Thresholds – An Example .....................................................................................................................................................................27
Pulse Input - Latching ........................................................................................................................................................................... 28
Configure Formulas .........................................................................................................................................................................29
Current Input Pin: ................................................................................................................................................................................ 30
Other Input Pin: ................................................................................................................................................................................... 30
Output Pin = ......................................................................................................................................................................................... 30
Constant Value = .................................................................................................................................................................................. 30
Correction: ........................................................................................................................................................................................... 30
Min Range: ........................................................................................................................................................................................... 30
Max Range: .......................................................................................................................................................................................... 30
Max – Min Range ................................................................................................................................................................................. 30
Min Units:............................................................................................................................................................................................. 30
Max Units: ............................................................................................................................................................................................ 30
Max – Min Units: .................................................................................................................................................................................. 31
Ent ........................................................................................................................................................................................................ 31
Sub ....................................................................................................................................................................................................... 31
Add.......................................................................................................................................................................................................31
Mul....................................................................................................................................................................................................... 31
Div ........................................................................................................................................................................................................ 31
Xch .......................................................................................................................................................................................................31
An explanation of the standard conversion formula ........................................................................................................................... 31
Programs .........................................................................................................................................................................................33
Program Edit Fields .............................................................................................................................................................................. 34
Function Library ................................................................................................................................................................................... 34
LOG AND LOGGING ........................................................................................................................................................ 35
Set Up and Management .................................................................................................................................................................35
Logging Rules...................................................................................................................................................................................35
Digital Inputs ........................................................................................................................................................................................ 35
Analog, Pulse, and Numeric In puts ...................................................................................................................................................... 35
Digital Outputs ..................................................................................................................................................................................... 35
Numeric Outputs.................................................................................................................................................................................. 35
THE CONTROL PANEL ..................................................................................................................................................36
Provisioning the Control Panel ........................................................................................................................................................36
APPENDIX A – FUNCTION LIBRARY .........................................................................................................................38
Function List ....................................................................................................................................................................................38
Function Descriptions ......................................................................................................................................................................38
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Digital I/O – Set .................................................................................................................................................................................... 38
Numeric I/O – Set................................................................................................................................................................................. 39
Math functions..................................................................................................................................................................................... 39
Note on Remote Commands ................................................................................................................................................................ 40
Remote I/O - Set................................................................................................................................................................................. 40
Note On Timer/Counter ....................................................................................................................................................................... 40
Timer/Counter/Ext/Clk – Start [Note – Changed In Release 4.02.02]................................................................................................. 42
Timer/Any – Stop ................................................................................................................................................................................. 43
Important Notes on Motor Group Control .......................................................................................................................................... 43
Motor Group Control ........................................................................................................................................................................... 44
Application Status - Set ........................................................................................................................................................................ 45
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Table of Figures
FIGURE 1 – THEORY OF OPERATION ................................................................................................................................................1
FIGURE 2 - TOP LEVEL NAVIGATION ...............................................................................................................................................2
FIGURE 3 - AUTOMATION CONTROL CONFIGURATION MENU..................................................................................................4
FIGURE 4 - UNIT CONFIGURATION....................................................................................................................................................5
FIGURE 5 - MANAGE I/O MODULES...................................................................................................................................................7
FIGURE 6 - MODULE ADD SCREEN....................................................................................................................................................8
FIGURE 7 - MODULE DELETE SCREEN .............................................................................................................................................9
FIGURE 8 – I/O MODULE REPLACEMENT.........................................................................................................................................9
FIGURE 9 - DISABLE I/O MODULE....................................................................................................................................................10
FIGURE 10 - ENABLE MODULE.........................................................................................................................................................10
FIGURE 11 - OUTPUT CONFIGURATION SCREEN .........................................................................................................................11
FIGURE 12 OUTPUT - PHYSICAL/DIGITAL .....................................................................................................................................12
FIGURE 13 - OUTPUT VIRTUAL/DIGITAL .......................................................................................................................................12
FIGURE 14 - OUTPUT VIRTUAL/NUMERIC .....................................................................................................................................13
FIGURE 15 - OUTPUT PIN DEFINITIONS..........................................................................................................................................14
FIGURE 16 - INPUT CONFIGURATION SCREEN .............................................................................................................................15
FIGURE 17- INPUT PHYSICAL/DIGITAL ..........................................................................................................................................16
FIGURE 18 - INPUT PHYSICAL/ANALOG.........................................................................................................................................16
FIGURE 19 - INPUT PHYSICAL/PULSE .............................................................................................................................................17
FIGURE 20 - INPUT VIRTUAL/DIGITAL ...........................................................................................................................................17
FIGURE 21 - INPUT VIRTUAL/NUMERIC.........................................................................................................................................18
FIGURE 22 - INPUT PIN DEFINITIONS..............................................................................................................................................21
FIGURE 23 - INPUT SOURCES (DIGITAL) ........................................................................................................................................22
FIGURE 24 - INPUT SOURCES (DIGITAL VIRTUAL)......................................................................................................................22
FIGURE 25 - INPUT SOURCES NUMERIC.........................................................................................................................................23
FIGURE 26 - INPUT DEFINITIONS (NUMERIC) ............................................................................................................................... 24
FIGURE 27 - ANALOG INPUT PROCESSING....................................................................................................................................26
FIGURE 28 - THRESHOLD AND DIRECTION...................................................................................................................................27
FIGURE 29 - INPUT FORMULA SELECTION SCREEN....................................................................................................................29
FIGURE 30 - EDIT INPUT FORMULA.................................................................................................................................................30
FIGURE 31 - STANDARD CONVERSION FORMULA ...................................................................................................................... 32
FIGURE 32 – PROGRAM SELECT.......................................................................................................................................................33
FIGURE 33 – PROGRAM EDIT SCREEN ............................................................................................................................................34
FIGURE 34 - CONTROL PANEL SELECTION AT LOGIN................................................................................................................ 36
FIGURE 35 - SAMPLE CONTROL PANEL DISPLAY........................................................................................................................37
Application Note – Automation Control Application
APN007 25 July, 2014
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Introduction:
Ctek's Automation Manager is an optional firmware application available for the Ctek Z4200/Z4400 series SkyRouter. It provides the logic and control necessary to create sophisticated automation applications that evaluate analog, digital, and pulse sensor inputs, and, based on sensor inputs, and programming logic, control output devices. The Automation Manager also provides a simple, GUI based rapid development environment used to create and deploy applications using the Automation Manager
Theory of Operation
Figure 1 depicts the high-level operation of Ctek’s Automation manager. The text below figure 1 explains the flow of information through the Automation Manager.
Figure 1 – Theory of Operation
The Automation Manager is an intelligent controller, implemented in software that reacts to inputs by controlling outputs. In their simplest form inputs are a sensors representation of a real world value e.g. temperature, pressure, open, closed, etc. And, in their simplest form outputs are control signals directed back into the real world to start motors, light lights or turn on heaters. The class of inputs and outputs coming from the real world and directed back into the real world are called physical inputs and outputs. Inputs are connected to outputs by programs. A program can only be initiated by an input. On an input the initiation of a program occurs as a result of the input reaching a defined state or threshold. For digital inputs the thresholds are true and false while for analog, pulse, and numeric inputs there can be many threshold values assigned to a single input, each capable of initiating its own program. In summary physical inputs receive information from sensors and, at predefined thresholds react to that information by initiating programs that control outputs. There is another class of inputs and outputs that are known as virtual inputs and outputs or virtual pins. Virtual pins exist only within the scope of the Automation Control software, they have no physical connection. Virtual pins can be read and written to, modified by Boolean calculations
Application Note – Automation Control Application
APN007 25 July, 2014
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(digital), basic math functions (numeric), and can be assigned event thresholds. Virtual pins are useful to modify processing logic, store intermediate results, and to display values derive from programs. Just like physical pins virtual inputs are temporary while virtual outputs are persistent.
Note – This document often refers to inputs and outputs as pins or input pins or output pins or
virtual pins depending on their origin.
Navigation and Top Level Functions:
When installed the Automation Control application is found under the applications selection on the top level SkyRouter administration screen. When selected, the application button presents the following navigation menu. The last two menu items shown below are related to the Automation Control option. Other menu choices may also appear depending on the set of features enabled on the SkyRouter.
Figure 2 - Top Level Navigation
Automation Control Panel
The Automation Control Panel selection provides user access to a dashboard style control and display of inputs and outputs that have been previously selected. Portions of this functionality are covered in Unit Configuration, Inputs, and Outputs discussion. A complete description of the Control Panel is found after the configuration section.
Automation Control Configuration
The Automation Control Configuration selection provides access to the screens used to configure the application characteristics of the overall application environment, the number and type of I/O modules installed, specific characteristics for each input and output on each I/O module, and the formulas and functions that are applied to specific sensors and outputs. For new installations the recommended sequence is:
1. Configure the unit
2. Configure the modules installed with this unit
3. Configure inputs on each installed module
Application Note – Automation Control Application
APN007 25 July, 2014
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4. Configure outputs on each installed module
5. Create and assign formulas as required
6. Create and assign programs as required
Once configuration has been completed the selections are deployed using the Execute New Configuration button. If logging is used the Logs selection can provide useful information about system operation and can also be used to debug sensor and output installations.
Application Note – Automation Control Application
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User Interface and Configuration Specifics
Selecting the Automation Control Configuration item presents the following menu from which the user can install, configure, and adjust settings on I/O modules and sensors.
Note: System Errors indicates entries made as a result of this application since the last time the
box was restarted. System errors can be caused by a number of events but one common source is communications problems with I/O modules. Contact Ctek or see TechNotes to recover the system log contents.
Figure 3 - Automation Control Configuration Menu
Execute New Configuration
The Execute New Configuration button must be pressed before any changes made on any edit screens will be deployed. The only exception to this rule is that outputs that are changed from their Output edit screen will take effect immediately and do not require a New Configuration. A new control panel view is also generated during a new configuration.
Unit Configuration
Selecting the Unit Configuration menu item causes the screen shown in Figure 4 to be displayed. A description of each field follows the screen image.
Application Note – Automation Control Application
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Figure 4 - Unit Configuration
Location Name:
A descriptive name assigned to this controller and its associated I/O modules
Application Note – Automation Control Application
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SMS Remote Control:
Enable or disable SMS read/write control/monitoring of automation control I/O pins. (Introduced in release 4.2 – see TechNote TN009 for details)
Authorized Phone Numbers:
A list of between 0 and 5, 10-digit, space separated phone numbers that are permitted to use the SMS Remote Control feature. A blank field blocks all phone numbers. The * (star) character allows any number. Although its use is not recommended the * character will also permit SMS control via the carrier’s email to SMS gateway.
Logging On/Off:
Enable or disable logging. Log files are formatted in the comma separated value (CSV) format and can be read and manipulated with a spread sheet program such as Excel. Inputs are logged at a rate defined on each input pin. Output logging is set to either on or off on each individual output pin. See Logging rules section.
Alarms On/Off:
Enable or disable alarms for the entire controller. Alarms can also be enabled or disabled for each individual input.
Alarm Delivery Method:
Select whether alarms will be delivered by SMS (text messaging), email, or both.
Send Lat/Lon:
Send the current position (latitude and longitude) of the unit with all alarm entries, both SMS and email.
Destination Phone Number for Alarms:
The phone number of the handset or device that will receive SMS alarms.
Destination email address for Alarms:
The email address that will receive alarms
Log Delivery Parameters:
Logs are files containing comma separated values that can be directly read into a spread sheet or database application. Logging options are available for each input and output. Logs can be delivered by email on a schedule established in this panel.
Email address for this device:
If the controller is going to send email alarms and logs it will require an email address to use as the sender. This is typically an email address from the customers email domain. All boxes in a network can use the same email address.
Email User Name and Password
Login information for the SkyRouter email client to use when connecting to the customer's email server to send alarms and reports.
SMTP Server Address and Port:
Information required about the customer's email server so the SkyRouter can connect to it to send reports and alarms.
Application Note – Automation Control Application
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Authentication and SSL Encryption:
Settings specific to each email SMTP server.
Display Group Names:
User assigned names of logical groupings of inputs and outputs that will be used to organize the display of the Control Panel. Both inputs and outputs can be organized under a single group name. For example a Power Control group could have a button to turn on/off power and a current measurement to display the amount of current being drawn.
I/O Modules
The I/O modules screens allow the user to Add, Delete, Replace, Enable, or Disable an I/O module. When an I/O module is added its inputs and/or outputs are automatically assigned. For relay modules four outputs are automatically assigned. When adding a 16-port I/O module eight unassigned (not initialized) inputs and eight digital outputs are automatically created. Inputs and outputs are assigned sequential numbers as modules are installed. To convert an unassigned input or output to a specific type (analog, digital, pulse, or numeric) the Configure Inputs and Configure Outputs screens are used to select a specific edit function for the selected pin type. Replace is a special case designed for maintenance. When using the replace function only the boards address may be changed and the pre-existing configuration will be assigned to the new address. The Replace function is useful for both replacing a defective module and to re-address an existing working module. The Enable and Disable functions apply only to physical modules. When a physical module is disabled it is taken out of the communications processing meaning that it is not polled. All settings remain intact and when the module is re-enabled communications will resume. This feature can be useful in troubleshooting communications problems when multiple modules are on one string.
Figure 5 - Manage I/O Modules
Application Note – Automation Control Application
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ABOUT I/O MODULE ADDRESSING
I/O module part numbers B1204S (4-port relay), B1216S (16-port) and Z1216S use RS485 communications. A default address of 99 is assigned to these modules when they leave the factory. Their addresses may be reassigned under program control from the replace function under the Configure I/O Modules screen. To readdress these modules first add them (Add function) as module address 99. Once added the module may be selected by its module number (not address) and readdressed by doing a replace on that module number with a similar type module assigned a different address.
NOTE – If a module assigned address 99 is already installed it will either have to be temporarily
disconnected from the RS485 string (use Disable) or readdressed using the process below before an additional module can be installed using this process. When a module is readdressed all of its input and output settings are retained so there is no penalty for readdressing a module currently addressed at 99.
Add:
Add is used to create a new module. When Add is selected the screen shown in Figure 6 will be displayed. A module type and module address are assigned by the user and submit is pressed. The newly created module will then be displayed in the module inventory and its associated inputs and/or outputs will be displayed on those screens. As previously discussed all newly created modules having inputs will be created with all inputs defined as unassigned. An RS485 module should be assigned a two character hexadecimal address between 01 and FF. RS485 address 00 is reserved for Ctek's PowerMinder module. USB modules are assigned an eight character address which is supplied with the module.
Figure 6 - Module Add Screen
Delete:
Delete is used to remove a module from the overall configuration. When selected the Delete screen will be displayed as shown in Figure 7. To delete a module enter the modules number and press submit. When a module is deleted all of its input and output settings are permanently erased.
Application Note – Automation Control Application
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Figure 7 - Module Delete Screen
Replace:
The replace function has three purposes. First it is used to replace an existing module with a spare. Secondly it can be used to readdress an existing module. In either case all settings associated with that module will be preserved.
When selected the Replace Module screen will be displayed as shown in Figure 8. To replace a module in the inventory enter the module number and the address to be assigned to the new module, and press submit. The input/output configuration of the old module is assigned to the new address.
Figure 8 – I/O Module Replacement
Restore a Modules Default Address
The replace function can also be used to restore the default (address 99) setting of a module. To accomplish this connect the module with the unknown address to an SkyRouter Automation controller. Using the Add function add the module with any address. At this point the module will not function properly but will appear in the module line up with the address assigned. Next, using the replace function replace the module having the made up address with the text default in the address field. The module will be assigned an address of 99 and after a program reload will begin functioning at that address. Once this is accomplished the module can then be readdressed (again using the replace function) to any address desired.
Application Note – Automation Control Application
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Note:
The default commend described above uses a broadcast that will set the address of all physical modules to 99. You may want to disconnect modules from the line up that do not require their address to be resored to default.
Disable
Disabling a module removes it from the communications routine. All set up information for the disabled module remains intact. Disable can be a useful troubleshooting tool when diagnosing communications problems or configuration issues.To disable a module enter its module number and press submit.
Figure 9 - Disable I/O Module
Enable
Enabling a module returns a disabled module to service. Setting previously stored on the module will be used. To enable a module enter its module number and press submit.
Figure 10 - Enable Module
Application Note – Automation Control Application
APN007 25 July, 2014
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Configure Outputs
A representative portion of the Configure Outputs navigation screen is shown below. This is a selection screen. Use the Type pull-down and Edit button to select a specific Output for edit. To completely disable an output select Disabled in the pull-down and then press the associated edit button. The default display shows the current status of outputs across all modules. Output pins are assigned numbers and displayed sequentially starting with the first module installed
Note: Output values are managed in one of four ways:
1. From the individual output's edit screen (output state field or current value + Submit)
2. By an On/Off button on the Control Panel
3. By the Shutoff Timer value on an output
4. Under program control by functions that are triggered by the threshold values of inputs
NOTE:
Each of these methods of changing an output state operates independent of the other, meaning that one method might change the state of an output pin and another method could immediately change it back. In other words an output manually turned on could be switched off by a threshold when it is reached.
Figure 11 - Output Configuration Screen
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