1. Jake Baldwin Krista Hasling Maryam Moghaddam-Zadeh Jack Oakes Scott Wisdom

2. Project Overview S.C.A.D.A. system Manna Energy Foundation, Rwanda Water Purification Project Objective Remotely determine system health Perform control operations based on use (autonomous and supervisory) Report and record

3. Features This design goal: 32 External ADC’s 6 Relay/Valve controls 4 Bus Power 3 Bus Data GSM communication Memory SD card Demo will not include max number of sensors

4. Structural Setup

5. Supply PV BatteriesPower Pumps, UVs Analog Memory MC Base Station AntennaGSM System Block Diagram

6. Layout

7. Supply PV BatteriesPower Pumps, UVs Analog Memory MC Base Station AntennaGSM System Block Diagram

8. PCB Layout – Power Converters

9. Schematic for 3.3V buck converter Uses LM3100 Chip Same as 5V and 10V buck Supplies max currents of 1.5 A Predicted max current needed is <1 A

10. Schematic for 12 V Buck-Boost Uses LM5118 Converter can supply a max current of 3.5 amps Predicted Max current < 1.5 Amps

11. Schematic for 24V Boost Uses LM3488 Max current of 3.4 Amps Predicted max value <1 Amp

12. Progress Converters and PCB are designed and ordered No implemented circuit protection yet…. Separating headers on current PCB will be removed for finished project

13. Supply PV BatteriesPower Pumps, UVs Analog Memory MC Base Station AntennaGSM System Block Diagram

14. Sensors Progress Pressure Meter 1 Pressure Meter 2 Flow Meter UV light Valve 12 Vdc 5 Vdc 24 Vdc 240 Vac ADC ADS7828 MC ATxmega 64A1 I2CI2C 0- 5 Vdc 2- 40 mA 0- 12 Vdc 0- 5 Vdc 3.3 Vdc 0- 12 Vdc

15. Analog/Digital Converter

16. Sensors Flow Meter Signet 2551 No device due to cost ($1500 each) Using a direct current output to act as device in testing 2 devices per system Output: 4 to 20 mA Temperature: -20° to 70° C Pressure Meter Omega 209 2 devices for testing 6 devices per system Output: 0 to 5 V at.0125 V/division Temperature: -20° to 80° C

17. Sensors Terminal Block PT 1935006 PCB attachment for ADC to sensors 16 connections Brass Actuated Ball Valve DynaMatic AP20DA 1 device for testing Temperature: -15° to 300 ° C UV lights Sterilight with ICE controller 1 device for testing Water temperature: 2° to 40° C UV wavelength: 254 nm SP100-HO: 11 gpm 9000 hours of use

18. Current System

20. Water Collection Tank Water Storage Tank Filter 1 UV light 1 UV light 2 Pressure Flow Our System

21. *No Flow Meter due to cost Expo Demo Setup Pressure UV light Valve “Flow” Pump

22. Supply PV BatteriesPower Pumps, UVs Analog Memory MC Base Station AntennaGSM System Block Diagram

23. Microcontroller – ATxmega64A1 Calibration of internal 32 MHz RC DFLL oscillator Initialize and use communication modules SPI I 2 C UART Sample sensors with timer interrupt Log data to SD Card Parse and execute commands from cell module and base-station Monitor and control using programmed algorithm

24. Image source: http://www.atmel.com/dyn/resources/prod_documents/doc8067.p df SD Card RS-232 Debug Port ADC PDI Port SPI UART DMA I2C Buses and Connections 32kHz XTAL Serial-to- USB IC (to base- station) Cell Module ATmega32

25. Code Flow Initialize modules Power on Idle Sample sensors Timer 1 interrupt Write measurement to SD Card over DMA Read measurement from SD Card Send Measurement Over Cell Measurements satisfy algorithm conditions? Perform algorithm results of satisfied conditions Yes READ Parse command Return to Idle No Command from base-station or cell Other base- station/cell commands... WRITE XXXX

26. Monitor and Control Algorithm Structure of one software algorithm block … With additional blocks, control is a “sum of products” Condition 1 Condition 2 Condition n & &… Result 1 Result 2 Result n & & …

27. Monitor and Control Algorithm Condition types: Threshold(Value, Above/Below, SensorID) True/False(Condition) Result types: ChangeValve(Closed/Open) ChangeRelay(On/Off) SendAlert(AlertType, Method, Value)

28. Memory – SD Card Use 512-byte block size Microcontroller allocates 512-byte buffer that can be read or written to SPI at 4MHz Hash table between time stamps and block addresses (grouped by day and hour)

29. Memory: Schematic

30. Memory: Process Flows for SD Card SD Card Initialization: SD Card Read Cycle: SD Card Write Cycle:

31. GO_IDLE_STATE trace SEND_OP_COND trace

32. Supply PV BatteriesPower Pumps, UVs Analog Memory MC Base Station AntennaGSM System Block Diagram

33. GSM Cellular AVR-GSM Calling card Embedded antenna Direct interface for USB terminal communication Off board connectors for power and buses

34. FBD: GSM Module Serial Interface SIM300D FTDI SERIAL-USB ATMEGA32 I2C XMega Laptop 12 Volt DC Prototype Components 2 PIN Power EXT I/OUSB PORT 6 pin ISP 26 Pin IO I2C -DAQFactory -Real Term -Prototype power -’Wall’ power

35. GSM Cellular ATxmega64 /ATMega32 SIM300 Bus/ATMega32 I2C with defined commands ‘Get’ and ‘Set’ 2 Buffers Data Transmit (~160 byte) Data Receive (~160 byte) 100Khz ~ 400Khz External connections 12V, GND, SCL, SDA ISP programmer UART commands ‘AT’ ASCII commands 2 Buffers UART RX 256 bytes UART TX 256 bytes 3x30 SIM300 Buffers Status buffer/byte 115K2 desired

36. Code Flow Peripheral Init (UART, I2C) Status ByteCellular Init Monitor Traffic Update Status GSM Data Received Update Status No Data Yes MCU Data Request Forward No Data Available MCU Command Back to Monitor Traffic MCU Send Data

37. GSM Cellular - Progress + Text messaging works (AT&T) + Uart for ATmega32 works (interrupt) + I2C master configured for ATMega32 (interrupt) - Needs to be slave + Fully defined status byte, bus protocol - Perform simple Uart/I2C test via terminal

38. Supply PV BatteriesPower Pumps, UVs Analog Memory MC Base Station AntennaGSM System Block Diagram

39. BaseStation Base Station

40. Base Station Two ways of communication: Serial to Microcontroller (and ADC) Serial to GSM module Two drivers on DAQFactory Two sets of Sequences GSM cell needs AT parsing

41. GSM Communication DAQFactory now communicates with GSM cell

42. MCU Communication Will Communicate with ADC through STK 500 Dummy microcontroller Atmega 32 Transmit commands and receive status

43. Interface Commands Cmd TypeCommandsCmdTx ParametersTxRx ParametersRx GET_StatusSensor (ADC)0x01 Cmd, Sensor ID (1- 32) (0x01-0x20) \x01 \x02 Cmd, Sensor ID, Data length (12 bits), Data Measured \x01 \x02 \x0F – Pressure \x65 Relay State 0x02 Cmd, Relay ID (0x01-0x04) \x02 \x04 Cmd, Relay ID, Data length (8 bits), State \x02 \x04 \x01 \x00 - Not Flipped Valve State 0x03 Cmd, Valve ID (0x1-0x2) \x03 \x01 Cmd, Valve ID, Data length (8 bits), State \x03 \x01 \x01 - Open Power Sensor 0x04 Cmd, Sensor ID (0x1-0x4) \x04 \x03 Cmd, Sensor ID, Data length (12 bits), Data Measured \x04 \x03 \x0F – Power Value \x01 Memory (Block) 0x05 Cmd, Day (0x0-0x1F), Beginning Hour, Ending Hour (00-23)(0x00-17) \x05 \x10 \x11 – 11am \x14 Cmd, Day, Beginning Hour, Ending Hour, Data length (512 Bytes), Measurements \x05 \x10 \x11 – 11am \x14 \x200 \23…. Memory (Recent Measurement) 0x06 Cmd, \x06 Cmd, Data length (64 Bytes), Measurements \x06 \x40 \x23…. MOD Status 0x07 Cmd, MOD ID (0x1-0x3) \x07 \x01 Cmd, MOD ID, Data length (8 bits), Status \x07 \x01 \x00

44. Interface Commands Cmd TypeCommandsCmdTx ParametersTxRx ParametersRx SET_Status Data Logging Mode 0x11 Cmd, Log Mode ID (0x01-0x02) \x11 \x01 Cmd, Log Mode ID, Data length (8 bits), Confirmed State \x11 \x01 \x01 – Was set! And begins logging Data.. Relay State 0x12 Cmd, Relay ID (0x01-0x06) Relay State (00 or 01) \x12 \x04 \x01 Cmd, Relay ID, Data length (8 bits), Confirmed State \x12 \x04 \x01 \x01 - Was Flipped! Valve State 0x13Cmd, Valve ID (0x1-0x2) \x13 \x01 Cmd, Valve ID, Data length (8 bits), Confirmed State \x13 \x01 \x01 – Was Opened! IDSensorRelayValvePower SensorMODLog Mod 0x01Pressure 1Relay 1Valve 1PS 1MicrocontrollerKeep logging 0x02Pressure 2Relay 2Valve 2PS 2 GSM Cell (Signal Strength, etc.) Stop logging until requested! 0x03AC Current 1Relay 3PS 3DAQFactory 0x04AC Current 2Relay 4PS 4 0x05Temperature 0x06 0x07 …..

45. DAQFactory User Interface

46. Division of Labor

47. Budget Sub-SectionComponentQuantity Unit Cost Running Total CostDate Purchased PowerPower Components1 $ 65.00 IC's10 $ 4.50 $ 45.00 SensorsADS78285 $ -Sample MAX3377EEUD2 $ -Sample TPIC26032 $ -Sample RELAY2 $ 2.50 $ 5.009/21/2009 Omegadyne2 $ 100.00 $ 200.00 Phidgets2 $ 30.00 $ 60.009/16/2009 DynaMatic1 expensive9/19/2009 Memorymemory card pin out board1 $ 18.00 Main ProcessorUSB2 $ -Sample max32321 $ -Capstone sample Serial db92 $ -Sample Header pins atxmega stk6001 $ 102.00 CellularPIC-GSM1 $ 275.00 8/24/2009 AVR-GSM1 $ 250.00 9/15/2009 SIM CARD2 $ 15.00 $ 30.008/31/2009 PIC-DEV board1 $ 107.00 8/24/2009 D-26 pin2 $ - Header 6-pin2 $ - Header 6-pin2 $ - BaseStationDAQ-FACTORY (Starter)1 $ 45.00 PCB OrdersProto PCB2 $ 33.00 $ 66.00 Shipping1 $ 14.88 Packaging Integration Capstone DEMO Total Available Currently SpentRemaining UROP Funding$800.00 $ 292.88$507.12 EEF?? Manna Energy$2,000.00 $ 990.00$1,010.00 Running Totals$2,800.00 $ 1,282.88$1,517.12

48. Milestone 1 Power Converters-efficiency numbers at different load conditions Physical Demo Constructed ADC and uC working together (with dummy test voltages) Physical connections for out-of-box items design completed GSM receiving text messages through serial port I2C slave functional – GSM module GSM module commands working Read/Write to SD card I2C functional Define Communications Protocol Retrieve sensor data Retrieve requested data in base module from remote module – on-site One-way communication between base station and uC – through text

49. Milestone 2 Power circuit protection implemented Physical connection to battery and PCB designed All sensors connected to ADC AC power safely working Sensors and ADC working together ADC data written to SD card using timer interrupts Implementing Basic Set commands Hard-coded antonymous control algorithm GSM two-way functionality with uC Parse received commands and update status in DAQFactory

50. Questions?