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BL1200 - Digi International

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1. U19 Watchdog Timer CE atl gt Crystal 04 EPROM Reset Button SZ J5 OC os J Z180 s ini 5 011 U2 ame R ue 8 De nate e ye n sis 014 J8 09 7 88485 5 P1 K u12 Driver Real Time Clock a Rs485 5 05 15 6 i us Driver Power Optical Isolator Optical Isolator uto J14 T f 2 O ddo I 6 cinogmnampougug adaaaguoggugouguu O H3 Optically Isolated H2 Power H1 Relay Driver Inputs Serial Ports Outputs Figure 1 1 BL1200 Controller Expansion boards may be connected to the BL1200 s 26 pin PLCBus to handle moderate or large control jobs all at moderate cost The BL1200 differs in several ways from other low cost programmable logic controllers widely used in industry The BL1200 is programmed in C a well known high level language This saves having to learn other coding schemes such as ladder logic The BL1200 s open board design costs less and provides more mounting flexibility than closed frame designs
2. ke ke ke he he ke he ke ke e ke ke ke ke ke Seelnput C Reads BL1200 s optically isolated input channels Fe e He He He RRR RIK KR REI KKK He He e He RRR RARE EERE int i j 4 16 1 j inport PIODA read input word print x j write to STDIO for i 0 i 30000 1 pause Procedure 1 Once the PC is properly linked to the BL1200 start Dynamic 2 Install the two 2 inch jumper wires between socket 8 on header H2 VCC and sockets 1 and 2 on header COMI 2 as shown This provides 5 V to the common lines that enable the eight input ports 3 2 T H1 000000000 00000900 00000000 00000001 0000000000 If the RS 232 to RS 485 converter is used socket 8 of header H2 will get rather crowded with wires Make a T from jumper wire then insert its tail in the socket 98 Sample Projects BL1200 3 Open SEEINPUT C in the SAMPLES subdirectory 9 Press F3 to compile and F9 to run the program The watch window and STDIO window will appear The STDIO window will display a hexadecimal value representing the status of the eight input channels approximately twice a second With none of the input channels pulled to ground hex FF indicates that each channel is a 1 Connect one end of a 4 jumper wire to socket 7 on header H2 GND or to so
3. 40 40 Serial Port 0 2 57 2 E A 90 BEELER 90 24 92 91 SEES ARK eonim 93 SETCLOCK etnies 104 setperiodic 35 shadow registers 88 slegp 35 software libraries een tmt 86 86 source C 59 source speed select 45 S90 crees 45 45 0 45 STATO teres 42 switching power supply 14 BYSOLOGK 40 system clock frequency 45 46 47 57 T eiae 45 TIDRE enn RR 43 45 45 technical manuals 53 Dynamic C 53 Hitachi inus 53 integrated circuits 54 0 54 Sprague oi 54 teet een tes 53 Index 113 TENDO en 44 43 time date clock 48 tm rd eas 49 transmitter data register 43 empty asco nmm iis 43 transmitter enable 45 transmitter interrupt enable 43 troubleshooting 5841 driver chip 58 eec 57 COM 57 communication mode 57 input output problems 58 memory 12 2 2 57 nonmaskable interrupts
4. programming TUM MOS nmt rs output relay driver enne OVETTUD icio tiere ceptus Darty entero even odd parity 0 PE 112 Index PLCBus 84 85 86 88 89 26 pin connector pin assignments 84 4 bit operations 85 87 8 bit operations 85 87 addresses 87 memory mapped I O register 86 reading data 86 relays DIP 84 89 writing data 86 ports Serial i enne nope 16 power fail oscillation 75 watchdog eee 75 power 18 clock frequency 36 COMMECHOM 18 Todes oie Ee ettet 36 power conservation 36 specification 18 switching 14 power failure interrupt 76 0 eerte 74 prescaler tete 46 programming 16 programming mode 96 R RAM battery backed 16 RDR 43 nnne 43 44 45 RE uiuo aeris 45 read data register full 43 read only memory 16 91 read24data 93 4 92 8 93 1200 reading data on the PL
5. gf 4 116 1 flasher 0 delay 5000 flasher 1 delay 5000 int delay int n int k for k 0 k gt n k Procedure 1 Once the PC is properly linked to the BL1200 start Dynamic C Open PFLASH C in the SAMPLES subdirectory Press F3 to compile and F9 to download the program to the BL1200 Exit Dynamic C Uh m Disconnect the power supply and switch the BL1200 from program ming mode to run mode 96 Sample Projects BL1200 Enable header J1 Connect a 2 inch insulated jumper wire from socket 8 on header H2 VCC to socket 2 on header COM2 Connect one end of a second 4 inch jumper wire to socket 7 on header H2 GND or to socket 10 on header H1 also GND Connect the other end of the 4 inch wire to socket 7 on header input channel 14 10 8 H2 110 H1 1 0000000000 00000000 0000000000 5000000 10000000000 6 Reconnect the power supply and press the BL1200 s reset button With the BL1200 now in run mode the LED will wink four times indicating that the new operating mode has been written to EEPROM The LED then blinks continuously as PFLASH runs from battery backed RAM Disable header J1 and disconnect the 4 wire 7 To prove that PFLASH C truly remains in RAM unplug the BL1200 s transformer power supply Plug the transformer back in after 10 20 s The LED will immediately
6. Table 1 Acronyms EPROM EEPROM NMI PIO PRT RAM RTC SIB2 SRAM UART Erasable Programmable Read Only Memory Electronically Erasable Programmable Read Only Memory Nonmaskable Interrupt Programmable Input Output Circuit Individually Programmable Input Output Programmable Reload Timer Random Access Memory Real Time Clock Serial Interface Board 2 Static Random Access Memory Universal Asynchronous Receiver Transmitter Conventions Table 2 lists and defines typographical conventions that may be used in this manual Table 2 Typographical Conventions 1 Example while IN 01 Italics Edit lt gt alblec Courier font bold indicates a program a fragment of a program or a Dynamic C keyword or phrase Program comments are written in Courier font plain face Indicates that something should be typed instead of the italicized words e g in place of filename type a file s name Sans serif font bold signifies a menu or menu selection An ellipsis indicates that 1 irrelevant program text is omitted for brevity or that 2 preceding program text may be repeated indefinitely Brackets in a C function s definition or program segment indicate that the enclosed directive is optional Angle brackets occasionally enclose classes of terms A vertical bar indicates that a choice should be made from among the items listed vii
7. sess 43 frequency system clock 45 46 47 57 H 07 18 high voltage driver 32 bd EWO oett tete oet dh 51 hv ALS 33 OTD 33 BV WE 33 BL1200 initialization constants 73 1 90 91 93 input optically isolated 13 30 98 intermittent operation 34 power supply 34 interrupt vectors 76 default 73 interrupts 43 73 76 85 88 nonmaskable 76 power failure 76 POUE dete epe urs 76 POUDES 88 76 jump vectors 76 j nipets 19 board locations 64 CONMECHONS 65 L 85 LCD bus urhe 85 85 libraries function 22 86 liquid crystal display 85 M T CIDOERY eren eto 14 battery backed 16 MODO teste 44 MODI uis 43 44 2 EORR 44 mode programming eee 96 96 modes addressing 87 Index 111 multiprocessor bit receive error flag reset bit mode 0 onboard operating clock frequency operating modes
8. 58 power supply 58 repeated interrupts 58 RS 232 to RS 485 converter 57 serial mk errori 58 watchdog timer 58 turnaround time master slave communication 38 V VORBE 34 114 Index W watchdog timer 51 52 58 51 writel2data 92 write24data 93 writed4data 92 write8data 93 writing data on the PLCBus 86 92 X IPS VOD ee ceteri pereas 84 e 84 XP8300 eee erecti teens 84 XP8400 ttti ert 84 XP8500 84 8600 2 0000001 84 XP8700 aucta 84 85 89 20 21 programming BL1200 20 troubleshooting 56 XP8800 treten 84 89 XP8900 iecit oe taret 84 Z ZIBO Port 73 2180 40 BL1200
9. Avariety of low cost expansion boards made by Z World and others allows the BL1200 to accommodate increased demands e open architecture of the BL1200 s expansion bus makes it easy to design add on boards The BL1200 s two RS 485 serial ports allow it to communicate easily with other devices 12 Overview BL1200 Features The BL1200 has eight optically isolated inputs eight relay driver outputs and two half duplex RS 485 serial communication ports Other standard features are battery backed RAM a battery backed real time clock two counters and a switching power supply These subsystems allow consider able flexibility to read inputs from switches and sensors and to control output devices such as high voltage or low voltage relays Optically Isolated Inputs The BL1200 s inputs incorporate NEC 2506 4 optical isolators as shown in Figure 1 2 The optical isolator includes two LEDs whose polarities are reversed to enable the inputs to accept current flowing in either direction The inputs even accept alternating current with the help of software that can detect a pulsing signal 5V 10 kQ Input to PIO AAA 4 3 Figure 1 2 BL1200 s Optically Isolated Inputs The standard 4 3 kQ load resistor accommodates input voltages of 3 V to 40 V which is well suited for detecting contact closures The BL1200 is protected from external voltage transients because the inter
10. BL1200 C Programmable Controller User s Manual 019 0013 040831 D BL1200 User s Manual Part Number 019 0013 040831 D Printed in U S A 1998 2004 Z World Inc All rights reserved Z World reserves the right to make changes and improvements to its products without providing notice Notice to Users Z WORLD PRODUCTS ARE NOT AUTHORIZED FOR USE AS CRITICAL COMPONENTS IN LIFE SUPPORT DEVICES OR SYSTEMS UNLESS A SPE CIFIC WRITTEN AGREEMENT REGARDING SUCH INTENDED USE IS EN TERED INTO BETWEEN THE CUSTOMER AND Z WORLD PRIOR TO USE Life support devices or systems are devices or systems intended for surgical im plantation into the body or to sustain life and whose failure to perform when properly used in accordance with instructions for use provided in the labeling and user s manual can be reasonably expected to result in significant injury No complex software or hardware system is perfect Bugs are always present in a system of any size In order to prevent danger to life or property it is the responsi bility of the system designer to incorporate redundant protective mechanisms ap propriate to the risk involved Z World products are 100 percent functionally tested Additional testing may include visual quality control inspections or mechanical defects analyzer inspections Specifications are based on characterization of tested sample units rather than testing over temperature and voltage of each unit Z World may
11. First Byte Addresses Full Address Encoding 4 bits x 3 0000 xxxx 0001 xxxx 0010 xxxx 0011 xxxx x0100 xxxxx x0101 xxxxx x0110 xxxxx x0111 xxxxx 1 0 00 63 16 384 1000 xxxxxx 1001 16 384 1001 1010 6bisxl 1010 1011 4bitsx1 1011 expansion register 8bitsx2 1 100 xxxxxxxx 0 0 1 1 8bitsx3 1 101 XXXXXXXX 1 0 1 1 110 1 10 1 1 1 1 bits 8 1 1 1 This scheme uses less than the full addressing space The mode notation indicates how many bus address cycles must take place and how many bits are placed on the bus during each cycle For example the 5 x 3 mode means three bus cycles with five address bits each time to yield 15 bit addresses not 24 bit addresses since the bus uses only the lower five bits of the three address bytes BL1200 PLCBus 87 Z World provides software drivers that access the PLCBus allow access to bus devices in a multiprocessing environment the expansion register and the address registers are shadowed with memory locations known as shadow registers The 4 byte shadow registers which are saved at predefined memory addresses are as follows SHBUSI SHBUS1 1 SHBUSO SHBUSO 1 SHBUS0 2 SHBUS0 3 Bus expansion BUSADRO BUSADRI BUSADR2 Before the new addresses or expansion reg
12. Run Program from Battery Backed RAM By switching the BL1200 from programming mode to run mode a program may be run from battery backed RAM eliminating the need for a serial link to a PC With the BL1200 running as a standalone controller it can be tested in the field with other equipment that is part of a system Later once the system has been refined and the program debugged the code can be burned into an EPROM For some applications it may be convenient to run the BL1200 from battery backed RAM indefinitely without burning a custom EPROM at all This would be appropriate for example for a system where the software is changed periodically or where the board is used temporarily and then changed to a new configuration Such a setup is feasible as long as the BL1200 s onboard battery remains in working order and an incorrect procedure or errant pointer does not accidentally corrupt the code stored in memory Usually for convenience and to ensure system reliability the final code should be burned into Materials Required One 2 inch piece and one 4 inch piece of solid core insulated 22 gauge jumper wire e Program PFLASH C provided with Dynamic BERR e ee e e e e e ee ke HK ke he ke ke ke ke ke ke ke ke PFLASH C flashes LED 0
13. Switching Power Supply The BL1200 s built in switching power supply accepts unregulated DC input of 9 V to 35 V This power supply conserves energy making the BL1200 suitable for many battery powered applications Expansion Bus A 26 pin PLCBus connector along one edge of the BL1200 provides two buses in one an LCD interface bus and the PLC expansion bus Various LCDs and keypad units can be used with the BL1200 through this connector Z World provides several expansion boards that connect directly to the 1 1200 on this bus You can create an extended system using a Z World controller and one or more expansion cards The cards communicate over the PLC bus and function as a single system User designed expansion boards can also connect to the BL1200 See Appendix D for more information on expansion boards oY Appendix E provides details on the PLCBus Memory Memory for running programs on the BL1200 is provided by a battery backed static RAM chip and an EPROM Memory chips from 32K to 512K are supported Another much smaller nonvolatile block of memory on the BL1200 is implemented with an EEPROM The EEPROM s 512 byte capacity stores semipermanent information such as bus addresses for the RS 485 commu nications ports or calibration constants The upper half of the EEPROM can be write protected 14 Overview BL1200 The BL1200 and its expansion boards can be mounted using plastic stand offs to any
14. 58 12 8 bit bus operations 85 87 89 power 1 18 A SED 18 board layout ss 12 AOK EN NITET 85 bus A1X A2X A3X 85 86 control registers 89 addresses digital inputs oe 89 encodIng auci nete reet 87 expansion 84 85 86 87 88 89 C 87 8 bit drivers 92 PLCBUS 87 44 1 88 applications neissent 16 devices 88 89 ASC a 44 functions 90 91 92 93 Control Register 44 rules for devices 88 Control Register B 45 software drivers 89 status registers MEC 42 85 asynchronous channel operation 44 operations asynchronous data transmission 39 Abit aisit 85 86 88 attention line 85 8 85 89 BU SADRO ente 86 87 B BUS ADR d ce 86 87 BUSADRJA eerie 86 87 background routine 88 BUSADR3 92 93 BL1200 Index 109 BUSRDI eee 89 90 BUSWR tete 90 C changing baud rate 26 CKA 44 disable nnne 44 CKAI TENDO oe 44 CKAJID ieiunii 44 CLOCK etes 49 clock frequency system 45 46 47 57 CNTLA iicet tms 43 CNTIEB tpe t trees 45 common problems programmi
15. XP8400 Eight low power SPST DIP relays XP8800 One axis stepper motor control XP8900 Eight channels of 12 bit D A converters Multiple expansion boards may GND VCC 5 V be linked together and con AOX IRDX LCDX ANRX nected to a Z World controller D1X DOX to form an extended system D3X D2X D5X D4X Figure E 1 shows the pin layout D7X D6X for the PLCBus connector GND 1 GND 0 0 2 GND OO A3X GND 0 0 strobe STBX 24V attention AT 5V VCC 2 0 1 GND Figure E 1 PLCBus Pin Diagram 84 PLCBus BL1200 Two independent buses the LCD bus and the PLCBus exist on the single connector The LCD bus consists of the following lines LCDX positive going strobe RDX negative going strobe for read WRX negative going strobe for write e A0X address line for LCD register selection e DOX D7X bidirectional data lines shared with expansion bus The LCD bus is used to connect Z World s OP6000 series interfaces or to drive certain small liquid crystal displays directly Figure E 2 illustrates the connection of an OP6000 interface to a controller PLCBus Yellow wire on top PLCBus Header Note position of connector relative to pin 1 From OP6000 KLB Interface Card Header J2 Pin 1 Figure E 2 OP6000 Connection to PLCBus Port The PLCBus consists of the following lines e STBX negative going strobe e AIX A3X three
16. routine at a time will run The EEPROM has a rated lifetime of only 10 000 writes un limited reads Do not write the EEPROM from within loop The EEPROM should be written to only in response to a hu man request for each write BL1200 EEPROM 81 82 EEPROM BL1200 E PLCBus Appendix E provides the pin assignments for the PLCBus describes the registers and lists the software drivers BL1200 PLCBus 83 PLCBus Overview The PLCBus is a general purpose expansion bus for Z World controllers The PLCBus is available on the BL1200 BL1600 BL1700 PK2100 and PK2200 controllers The BL1000 BL1100 BL1300 BL1400 and 1 1500 controllers support the XP8300 XP8400 XP8600 and XP8900 expansion boards using the controller s parallel input output port The BL1400 BL1500 also support the XP8200 and XP8500 expansion boards The ZB4100 s PLCBus supports most expansion boards except for the XP8700 and the XP8800 The SE1100 adds expansion capability to boards with or without a PLCBus interface Table E 1 lists Z World s expansion devices that are supported on the PLCBus Table E 1 Z World PLCBus Expansion Devices Device Description EXP A D12 Eight channels of 12 bit A D converters SE1100 Four SPDT relays for use with all Z World controllers XP8100 Series 32 digital inputs outputs XP8200 Universal Input Output Board 16 universal inputs 6 high current digital outputs
17. then the program can crash The shared keyword provided in Dynamic C can be used to prevent this type of situation 3 Hardware and software can interact Suppose for example that a function processes an A D conversion value that should always be positive If an electrical transient occurs because of the startup of a nearby motor which happens let s say only once a day then the value of the A D conversion may go negative and the program may enter an endless loop Once again the programmer has erred by not anticipating a negative value It is unlikely the error would be found through testing 52 System Development BL1200 References Z World Technical Manuals Z World technical manuals are available from Z World Inc Davis California Dynamic C Technical Reference manual A detailed description of Dynamic C with some instructions on use 7485 Coprocessor Instruction Manual Detailed information about installation and use of Z World s Z485 communications co processor board for IBM PCs Zilog Technical Manuals Zilog technical manuals may be ordered from Zilog Inc Campbell California Z80 PIO Technical Manual Describes in detail the parallel port used on the BL1200 Item no 03 0008 01 Z80 CTC Technical Manual More information on the counter timers used on the BL1200 Item no 03 0036 02 Z80 SIO Technical Manual Describes the SIO serial port of the BL1200 A necessity for most SIO programming especially synchron
18. three 4 bit addresses followed by a 4 bit data write to the control register The control registers are configured as follows bit3bit2 bitO A2 0 D The three address lines determine which output bit is to be written The output is set as either 1 or 0 according to D If the device exists on the bus reading the register drives bit 0 low Otherwise bit O is a 1 For digital input each register BUSRDO returns four bits The read register BUSRDI drives bit 0 low if the device exists on the bus 8 Bit Devices Z World s XP8700 and XP8800 expansion boards use 8 bit addressing Refer to the XP8700 and XP8800 manual Expansion Bus Software The expansion bus provides a convenient way to interface Z World s controllers with expansion boards or other specially designed boards The expansion bus may be accessed by using input functions Follow the suggested protocol The software drivers are easier to use but are less efficient in some cases Table E 5 lists the libraries Table E 5 Dynamic C PLCBus Libraries Library Needed Controller DRIVERS LIB controllers BL1200 PLCBus 89 There are 4 bit and 8 bit drivers The 4 bit drivers employ the following calls e void eioResetPlcBus Resets all expansion boards on the PLCBus When using this call make sure there is sufficient delay between this call and the first access to an expansion board LIBRARY EZIOPLC LIB EZIOPLC2 LIB EZIOMGPL LIB void e
19. A high level on the CTS pin forces this bit to 0 even though the transmitter is ready CTSIE CTS Enable Channel 1 The signals RXS and CTS1 are multiplexed on the same pin 1 stored in this bit makes the pin serve the CTS1 function A 0 selects the RXS function The pin RXS is the CSIO data receive pin The CTS line has no effect when RXS is selected It is not advisable to use the CTS1 function on the BL1200 because the RXS line is needed to control several other devices on the board RIE Receiver Interrupt Enable A 1 enables receiver interrupts and 0 disables them A receiver interrupt is requested under any of the following conditions DCDO Channel 0 only read data register full OVRN overrun PE parity error and FE framing error The condition causing the interrupt must be removed before the interrupts are re enabled or another interrupt will occur Reading the receiver data register RDR clears the RDRF flag The EFR bit in CNTLA is used to clear the other error flags FE Framing Error A stop bit was missing indicating scrambled data This bit is cleared by the EFR bit in CNTLA PE Parity Error Parity is tested only if MODI in CNTLA is set This bit is cleared by the EFR bit in CNTLA OVRN Overrun Error Overrun occurs when bytes arrive faster than they can be read from the receiver data register The receiver shift register RSR and receiver data register RDR are both full BL1200 S
20. GND K O8 06 04 2 07 05 03 01 Figure 4 3 BL1200 Relay Driver Do not connect to or remove wires from the relay driver output N ports with a relay or solenoid powered up Doing so can blow out the driver chip The Sprague driver chip is used Its voltage ratings are summarized in Table 4 1 Table 4 1 Sprague Driver Chip Specifications Breakdown Sustained Du Voltage Voltage Output UCN 5841A UCN 5842A UCN 5843A BL1200 System Development 31 The relay driver or high voltage driver is configured as shown in Fig ure 4 4 H1 1 O8 Serial Solenoid Interface O7 3 Hem 06 Voltage in ave 4 05 35 V 5841A 5 50 V 5842A 04 50 V 5843A 6 Sample Circuit 2 02 8 O4 35 V 9 Power K L Supply 10 TN 57 GND Optional Capacitor Figure 4 4 BL1200 Relay Driver Configuration Each channel is capable of sinking up to 500 mA The maximum allow able power dissipation is 1 82 W at 25 C Reduce this by 18 2 mW for each degree above 25 C The allowed power dissipation at 70 C for example would be 1 W The collector to emitter saturation voltage limits are listed in Table 4 2 Table 4 2 Relay Driver Collector to Emitter Saturation Voltage Limits Collector Emitter Power Voltage Dissipation V W Current mA 32
21. MPB is included in transmitted data start bit data bits MPB stop bits The MPB is 1 when MPBT is 1 and 0 when MPBT is 0 MPBT Multiprocessor Bit Transmit This bit controls the multiprocessor bit MPB When the MPB is 1 transmitted bytes will get the attention of other units listening only for bytes with MPB set 46 System Development BL1200 Table 4 6 shows ASCI Control Register B values for baud rates at various clock frequencies Table 4 6 Control Register B Values for Baud Rates at Various Clock Frequencies Rate 12 288 9 216 6 144 4 608 3 072 2 304 BL1200 System Development 47 Time Date Clock The battery backed time date clock also known as the real time clock or RTC uses the Epson 72421 chip The 72421A is accurate to approximately one second per day The 73421B is accurate to approximately five seconds per day Time is kept to one second least count and up to 80 years in the future The lithium battery should keep the clock going for about 10 years unless the board is stored at high temperature for long periods with the power off An Epson RTC 72421 battery backed clock appears to the rest of the controller as 16 I O registers occupying addresses 050 05 The 16 registers each four bits wide appear as the lower four bits of the data byte with the upper four bits undefined Table 4 7 shows how the registers are arranged As can be seen from Table 4 7 the 4 bit regis
22. The system reset is triggered when the regulated 5 V falls below 4 5 V the reset remains enabled as the voltage falls further At this point the chip select for the SRAM is forced high standby mode Power for the time date clock and the SRAM is switched to the lithium backup battery as the regulated voltage falls below the battery voltage approximately 3 V The power fail interrupt must be disabled if an external 5 V power supply is used not recommended The following sample routine demonstrates how to handle a power fail interrupt JUMP VEC NMI INT myint interrupt retn 5 body of interrupt routine for if powerlo return Normally a power fail interrupt routine will not return Instead it will execute shutdown code and then enter a loop until the 5 V falls low enough to trigger a reset However the voltage might fall low enough ina brownout situation to trigger the power fail interrupt but not the reset resulting in an endless hangup The library function powerlo returns if the voltage level falls below the NMI threshold otherwise it returns 0 This routine should be called only from an NMI interrupt routine If powerlo detects that the low voltage condition has reversed itself then the power fail routine can restart execution If a low but not fatally low voltage persists then you will have to decide what action to take if any The power1o routine for the BL1200 depends on a jumper being
23. at half the speed of the BL1200 s crystal Thus if 18 432 or simply 184 is stamped on the crystal case A speeds 0216 MHz 78 EEPROM BL1200 EEPROM Channels With header J1 enabled that is its two pins are connected the BL1200 when restarted by powering up or by pushing the reset button reads input channels 10 through I2 and 14 through I6 It then writes to the EEPROM data that determine the mode of operation when the BL1200 is later restarted without J1 enabled Each input channel if connected to VCC and GND is interpreted as follows Notice that channels I3 and 7 are not used 10 Set baud rate to 57 600 bps Set baud rate to 28 800 bps I2 Set baud rate to 9 600 bps 14 Set board for run mode I5 Initialize EEPROM clock speed 6 144 MHz 16 Initialize EEPROM clock speed 9 216 MHz Input channels 10 I1 and I2 are sockets 3 4 and 5 respectively on the BL1200 s header Input channels 14 I5 and I6 are sockets 7 8 and 9 on header H3 See Figure D 1 2 20 02 ss i i 0 1 412 413 415 416 417 Optical Isolators Optical Isolators PA4 PA7 4 15 16 7 202 WV WV EEPROM Input Channel Header H3 Socket COM1 2 10 11 12 14 15 l6 ooo 5 0 lt gt Figure D 1 EEPROM Channels BL1200 EEPROM 79 Note that when chann
24. control lines for selecting bus operation e D0X D3X four bidirectional data lines used for 4 bit operations e DA4X D7X four additional data lines for 8 bit operations e AT attention line open drain that may be pulled low by any device causing an interrupt The PLCBus may be used as a 4 bit bus DOX D3X or as an 8 bit bus DOX D7X Whether it is used as a 4 bit bus or an 8 bit bus depends on the encoding of the address placed on the bus Some PLCBus expansion cards require 4 bit addressing and others such as the XP8700 require 8 bit addressing These devices may be mixed on a single bus BL1200 PLCBus 85 There are eight registers corresponding to the modes determined by bus lines AL X A2X and A3X The registers are listed in Table E 2 Table E 2 PLCBus Registers Register Address Meaning BUSRDO Read data one way BUSRDI C2 0 0 1 Read data another way BUSRD2 C4 0 1 0 Spare or read data Read this register to BUSRESET en 0 reset the PLCBus First address nibble BUSADRO C8 or byte Second address nibble or byte Third address nibble or byte BUSWR CE 1 1 1 Write data BUSADRI CA BUSADR2 Writing or reading one of these registers takes care of all the bus details Functions are available in Z World s software libraries to read from or write to expansion bus devices To communicate with a device on the expansion bus first select a register associated with the de
25. installed between J1 pin 1 and J10 pin 1 This allows the NMI signal to be read by the input used for the programming header The dual use of this program ming header input can present a problem if the low voltage condition is present when the processor comes out of reset This will not happen nor mally because the reset lasts for about 50 ms after the 5 V passes the minimum threshold voltage of about 4 5 V However if the voltage fails to 74 Memory I O Map and Interrupt Vectors BL1200 rise from the reset threshold to the power fail threshold within 50 ms the program perceives that the programming jumper was installed since the NMI signal is low To force the programming jumper to be ignored al ways the EPROM FP02311 or latter revision can be edited to clear bit 0 at location OxE 15 decimal in the EPROM This will cause the program ming jumper to be ignored A situation similar to brownout occurs if the power supply is overloaded Say the load temporarily increases perhaps when an LED is turned on causing the power supply to appear to have failed The interrupt routine sheds some of the load by doing a shutdown procedure causing the power fail condition to go away If no action is taken to correct the overload the system will oscillate around the power fail To correct this use a larger power supply Do not forget the interaction that can occur between the watchdog timer and the power fail interrupt If the watchdog is ena
26. prescaler PS and the divide ratio DR the SS bits select the source internal or external clock and the baud rate divider as shown in Table 4 5 Table 4 5 Baud Rate Divide Ratios for Source Speed Select Bits 552 551 550 Divide Ratio 1 2 4 8 16 32 64 external clock 2 co 0 0 1 1 0 0 1 1 So 5 eS 0 System Development 45 The prescaler PS the divide ratio DR and the SS bits form baud rate generator see Figure 4 10 Prescaler ivi PS Divider Processor 1 Clock 10 2 or 0 0 64 Figure 4 10 Baud Rate Generator DR Divide Ratio This bit controls one stage of frequency division in the baud rate generator If 1 then divide by 64 If 0 then divide by 16 This is the only control bit that affects the external clock frequency PEO Parity Even Odd This bit affects parity 0 even parity 1 odd parity It is effective only if MODI is setin CNTLA parity enabled CTS PS Clear to Send Prescaler When read this bit gives the state of external pin CTS 0 low high When CTS pin is high RDRF is inhibited so that incoming receive characters are ignored When written this bit has an entirely different function If a 0 is written the baud rate prescaler is set to divide by 10 Ifa 1 is written it is set to divide by 30 MP Multiprocessor Mode When this bit is set to 1 multiprocessor mode is enabled The multipro cessor bit
27. zero wait states These times reflect the use of Dynamic C s library The time required to read from memory is included but the time Table C 1 BL1200 Execution Times Operation Time us DMA copy per byte 0 73 Integer assignment 3 4 Integer add 4 4 Integer multiply 18 Integer divide 90 Floating add typical Floating multiply Floating divide Long add Long multiply Long divide Floating square root Floating exponent Floating cosine to store a result is not Memory Access Times Two types of memory cycles must be considered LIR cycles which fetch the op code have the most critical timing requirement Some instruction cycles will be standard memory cycles the other type of memory cycle Standard memory cycles require an access time of 95 ns The following memory access times are required EPROM SRAM 9 216 MHz zero wait 122 ns 176 ns These times are very conservative Problems are unlikely for example if a 200 ns EPROM is used instead of one rated at 176 ns However the SRAM s access time must equal that of the EPROM during program devel opment or when executing code in SRAM because code executes from RAM during these periods BL1200 Memory I O Map and Interrupt Vectors 69 Tables C 2 to C 6 list the symbolic names for all the I O registers on the BL1200 These symbolic names are treated as unsigned integer constants Table 2 BL1200 Add
28. 32 128 J11 EEPROM T standard LEE 256K 512K E write enable POWER CONFIG J4 E EJ write protect 0 low power CE 64K 512K 4 gt O 01 numm X6 eg H U4 175 7 EPROM e ww Axe eet d gt Ls 16 5 2180 2 5 319 425 Y rg 22222 EERROM RAM u6 hacia Drm J11 014 J8 uo 846 5 P1 72 Driver x 2 PO 5 RS485 US u15 ug Driver Power Optical Isolator K u10 J14 6 gt 2 gt Q ee J1 OOOO OOC LIC EXEAETEAEAEAE TE AE 0 H3 H2 H1 J8 Enable J1 only to interrupt 2 on clock reprogram EEPROM power supply controlled by clock LE 32 128 y EE 256K 512K enable J2 RAM i power supply always on j do not connect J4 WATCHDOG Figure B 2 Locations of BL1200 Headers and Jumpers 64 Specifications BL1200 Table B 2 shows the jumper connections Table B 2 BL1200 Jumper Settings Description Factory Setting 1 Connect pins 1 and 2 only when Not connected reprogramming the EEPROM J2 Connect pins 1 and 2 for 32K 64K or Pins 1 and 2 128K RAM Connect pins 2 and 3 for connected 32K 256K or 512K RAM J3 Connect pins 1 and 2 for 32K 64K or Pins 1 and 2 128K EPROM Connect pins 2 and 3 for connected 32K 256K or 512K EPROM Connect pins 1 and 2 for 32K EPROM Pins 1
29. 6 MHz clock 0 4 W with 6 144 MHz clock N A Digital Inputs Digital Outputs 8 optically isolated 3 V to 48 V 8 channels sinking continuously 165 mA each at 50 C and 48 V DC channel sinking continuously 500 mA at 25 Analog Inputs Analog Outputs Resistance Measurement Input Processor Clock Speed 9 216 MHz SRAM 32K supports up to 512K EPROM 32K supports up to 512K Flash EPROM No EEPROM 512 bytes Counters Software implementable Serial Ports Serial Rate 2 RS 485 2 wire Up to 57 600 bps Watchdog Supervisor Yes Time Date Clock Yes Memory Backup Battery Yes 3 year shelf life 10 year life in use Keypad and LCD Display Supported through PLCBus PLCBus Port BL1200 Yes Specifications 63 Jumper and Header Specifications Figure B 2 shows the locations of the BL1200 headers and jumpers J3 EPROM 5
30. ARAMETER ch is the character to be written to the PLCBus LIBRARY EZIOPLC LIB EZIOPLC2 LIB EZIOMGPL LIB void writel2data int adr char dat Sets the current PLCBus address then writes four bits of data to the PLCBus PARAMETER adr is the 12 bit address to which the PLCBus is set dat bits 0 3 specifies the data to write to the PLCBus LIBRARY DRIVERS LIB void write4data int address char data Sets the last four bits of the current PLCBus address then writes four bits of data to the PLCBus PARAMETER adr contains the last four bits of the physical address bits 8 11 dat bits 0 3 specifies the data to write to the PLCBus LIBRARY DRIVERS LIB The 8 bit drivers employ the following calls void set24adr long address Sets a 24 bit address three 8 bit nibbles on the PLCBus read and write operations will access this address until a new address is set PARAMETER address is a 24 bit physical address for 8 bit bus with the first and third bytes swapped low byte most significant LIBRARY DRIVERS LIB 92 PLCBus BL1200 e void set8adr long address Sets the current address on the PLCBus read and write operations will access this address until a new address is set PARAMETER address contains the last eight bits of the physical address in bits 16 23 A 24 bit address may be passed to this function but only the last eight bits will be set Call this function only if the first 16 bit
31. CBus 86 91 receiver data register 43 receiver data register full 44 receiver enable 45 receiver interrupt enable 43 receiver interrupts 43 receiver shift register 43 relay driver eem 32 Output 13 31 software 2 2 22 33 r quest to send eee 44 reset expansion boards 90 reset from remote station 28 ROM programmable 16 RS 232 converter 19 20 RS 485 serial communication 14 19 serial POrts 37 RSR ueteres 43 RTSO 44 6 96 RXS icoocietendii ear t 43 S sample program 22 sample project control output channels 100 read input channels 98 read system clock 104 run program from RAM 96 test real time kernel 102 SETIO0O entere 84 SEEINPUT 5 98 select PLCBus address 90 serial communication 16 19 m 42 44 45 47 ne ee 37 serial interr Pt 76 Serial Port 0 ees 57 BL1200 serial ports 13 16 37 ASCI Status Regsiter 42 41 interrupt driven driver 42 Intetrrupts eee terres 41 polling type driver 42 programming
32. Channel 0 Shift Register Out CLKAO STATO BL1200 System Development 41 Polling Type Driver The polling driver tests the ready flags TDRE and RDRF until a ready condition for example transmitter data register empty or receiver data register full appears If an error condition occurs on receive the routine must clear the error flags and take appropriate action if any If the CTS line is used for flow control data transmission is halted automatically whenever CTS goes high because the TDRE flag is disabled This prevents the driver from transmitting more characters because it thinks the transmitter is not ready The transmitter will still function with CTS high but care must be taken since the synchronization bit TDRE is not available to properly synchro nize loading of the data register TDR Interrupt Driven Driver The receiver interrupt for an interrupt driven driver is enabled for as long as it is desired to receive characters The transmitter interrupt is enabled only while characters are waiting in the output buffer When an interrupt occurs the interrupt routine must ascertain the cause receiver data register full transmitter data register empty receiver error or DCDO pin high Serial Channel 0 only None of these interrupts is edge triggered so another interrupt will occur immedi ately if interrupts are re enabled without disabling the condition that caused the interrupt Channel DCDO is especiall
33. ROM electrically erasable programmable read only memory is used to store the constants and parameters listed in Table D 1 The four bytes presently in use determine the operation of the BL1200 board when it starts up Table D 1 BL1200 EEPROM Assignments Address Function Operating Mode 1 programming mode 8 run mode execute user program in RAM or EPROM on startup Baud rate code in units of 1200 baud Unit serial number Clock speed in units of 1200 Hz pot yet implemented The EEPROM has 512 bytes The upper 256 bytes can be written to only when header J11 is enabled pins 2 and 3 are connected Connect pins 1 and 2 on J11 to write protect the EEPROM When the EEPROM is first initialized the baud rate is set to 19 200 bits per second and the operating mode is set to programming mode The next section outlines the procedure to change these parameters Operating Mode In programming mode the board initializes Serial Port 0 for Dynamic C When set for run mode the board attempts to execute a user written program stored in battery backed RAM or in EPROM Baud Rate The baud rate code determines the serial communication rate at which the BL1200 attempts to communicate with the PC and Dynamic C Clock Speed The clock speed code is used by the BL1200 to compute parameters necessary to set the serial port The clock speed 18 also used by several Dynamic C library functions The clock operates
34. RT e b DON BD 366 FO i MHz Real Time Clock PIO 5 U5 Latch Uis m 85485 8 u2 2 P D u13 Driver ower i i RS 232 Driver e Optical Isolator Optical Isolator UL 0 U10 0 0 0 0 jack om 0000000000 00000000 3000000000 ee ut R1 R2 Di 02 LI TI H3 Optically Isolated H2 Power H1 Relay Driver Inputs Serial Ports Outputs RJ12 Connector 24V Bus Connector to serial cable GND to serial cable Figure 2 4 Use of 8700 to Program BL1200 4 The BL1200 is now ready for programming The power supply may be plugged in and turned on Running Dynamic C Test the Communication Line Double click the Dynamic C icon to start the software Note that the PC attempts to communicate with the BL1200 each time Dynamic C is started No error messages are displayed once communication is established See Appendix A Troubleshooting if an error message such as Target Not Responding or Communication Error appears Once the necessary changes have been made to establish communication between the host PC and the BL1200 use the Dynamic C shortcut lt Ctrl Y gt to reset the controller and initiate communication BL1200 Getting Started 21 Selecting Communications Rate Port and Protocol The communicati
35. Required tat ep ORE 18 Connecting the BL1200 to a Host PC seen 18 Running Dynamic C teer rene De e eee 21 Test the Communication 21 Selecting Communications Rate Port and Protocol 22 Running a Sample Program eene 22 Chapter 3 BL1200 Operation 23 Operating Modes ere Rn t HR TEE De Ere 24 Run Mode eee 25 Returning to Programming Mode 26 Changing Baud Rate on the 311200 sese 26 BL1200 Table of Contents iii Programming EPROMS 27 Choosing 27 e Re Hed pe ER 28 Downloading Programs from a Distance 28 Chapter 4 System Development 29 Optically Isolated 30 Relay Dnver emeret e bert 31 Software for the Relay Dnver acere ttr 33 Intermittent Operation nr treten re bb 34 Onboard EID ss 35 Power Conserving Configuration sse 36 Serial Ports iecore het eere bene e Ce tpe eyed desc eve ep es 37 Direct Programming of the Serial Ports 40 Rates c 41 Driving the Serial Ports tne ep Pere 41 PollinB Type Diver 42 Interrupt Dtiven Driver eet HERR tests 42 ASCI Stat s Registers eR pet te oap Deko Hope 42 ASCI Co
36. System Development BL1200 The output channels are designed to be able to drive inductive loads such as solenoids or relays The K line drains the inductive overvoltage If the wire connecting K to the power supply is long inductive install a filter capacitor near the board to absorb the voltage surge that occurs when a device is turned off If the protective diodes shown in Figure 4 3 are not connected inductive loads will blow out the chip When driving incandescent lights take care to protect the relay driver from overstresses caused by the initial inrush of current Software for the Relay Driver The following routine from the Dynamic C DRIVERS LIB library allows writing to the 5841 high voltage relay driver chip e int hv wr char v Writes 8 bits to the high voltage driver Each bit controls one high voltage output a 1 enables pulls low the corresponding output 0 disables the output Note that all eight bits are strobed to the output register in one clock cycle so all bits change simultaneously Bit 0 corre sponds to output O8 and bit 7 corresponds to output O1 This routine uses the 7180 CSI O serial interface to transmit one character to the relay driver chip e int hv enb Enables the 5841 output driver e int hv dis Disables the 5841 output driver The relay driver is not affected when a hardware reset occurs In situations where it is important to disable the relay driver if the system fails inst
37. a function s definition with an instance of its use in a listing Notending statements with semicolons Notinserting commas as required in functions parameter lists Leaving out an ASCII space character between characters forming a different legal but unwanted operator e Confusing similar looking operators such as amp amp with amp with with etc nadvertently inserting ASCII nonprinting characters into a source code file BL1200 Troubleshooting 59 60 Troubleshooting BL1200 SPECIFICATIONS Appendix B provides the dimensions and specifications for BL1200 controller BL1200 Specifications 61 Hardware Dimensions Figure B 1 illustrates the BL1200 s dimensions Figure B 1 BL1200 Dimensions in inches The BL1200 and its expansion boards fit in standard PC board holders designed to be mounted on a 35 mm DIN rail The BL1200 may also be mounted with screws and standoffs on any flat surface 62 Specifications BL1200 Table B 1 presents the specifications for the BL1200 series of controllers Table B 1 BL1200 Specifications Parameter Board Size Specification 4 33 x 2 835 x 0 85 110 mm x 72 mm x 22 mm Operating Temperature 40 70 C Humidity 596 956 noncondensing Input Voltage and Current Power Consumption User Configurable I O 9 36 V DC 66 mA at 24 V switching supply e 0 8 W with 9 21
38. all an independent turnoff mechanism for equipment controlled by the relay driver output channels If the BL1200 s power supply fails then the high voltage driver will be placed in the OFF state and will remain off when power returns If the 5841 chip fails because of overstress it can fail in the ON state allowing current to continue to flow Be sure to consider the consequences of any such failure and install appropriate protective systems BL1200 System Development 33 Intermittent Operation The BL1200 is equipped with a switching power supply which enables it to turn power on and off with software This is done either under the control of the time date clock or by installing an external switch The switching power supply turns off when the signal VOFF is raised high It turns on when VOFF is pulled low A power on reset lasting approxi mately 50 milliseconds occurs when the power supply turns on Computa tion begins in the program s main routine approximately 10 milliseconds after the reset ends VOFF can be driven by an external circuit or set permanently in the enabled low state by installing a jumper at header J10 It can also be controlled by the open drain output of the 72421 clock chip The power supply can be controlled in one of two ways 1 Install a manual pushbutton that grounds VOFF enabling the power supply The program then calls the library routine powerup to keep the power supply enabled after the operator
39. an be altered under software control The addresses are given in hex relative to the start of the interrupt vector page as determined by the contents of the I register These are the default interrupt vectors set by the boot code in the Dynamic C EPROM Table C 8 Interrupt Vectors for Z180 Internal Devices Address Name Description 0x00 VEC Expansion bus attention INT1 vector 0x02 INT2 VEC INT2 vector Battery backed timer interrupt when jumper J8 is set appropriately 0x04 PRTO VEC PRT Timer Channel 0 0x06 VEC PRT Timer Channel 1 DMAO VEC DMA Channel 0 DMA1 VEC DMA Channel 1 CSIO VEC Clocked Serial I O SERO VEC Asynchronous Serial Port Channel 0 SER1 Asynchronous Serial Port Channel 1 A directive such as the following is used to vector an interrupt to a user function in Dynamic C RINT 0x10 myfunction This particular statement causes the interrupt at offset 10H serial port 1 of the Z180 to invoke the function myfunction The function must be declared with the interrupt keyword interrupt myfunction BL1200 Memory I O Map and Interrupt Vectors 73 Nonmaskable Interrupts Power Fail Interrupts The following sequence of events takes place when power fails 1 The nonmaskable interrupt NMI signaling power failure is triggered whenever the unregulated DC input voltage falls below approximately 8 V subject to voltage divider R3 R4 2
40. and 2 Connect pins 2 and 3 for 64K or larger connected 32K EPROMs J5 For RAM Connect pins 1 and 2 for the Pins 2 and 3 low power configuration Connect pins 2 connected and 3 for the standard configuration standard J6 For EPROM Connect pins 1 and 2 for Pins 2 and 3 the low power configuration Connect connected pins 2 and 3 for the standard standard configuration J8 Connect pins 1 and 2 so that interrupt 2 Pins 3 and 4 will be triggered on the real time clock connected power Connect pins 2 and 3 so that the power supply always on supply is controlled by the real time clock Connect pins 3 and 4 so that the power supply is always on J10 When pins 1 and 2 are connected Not connected maskable interrupt NMI will cause a reset Dynamic C triggers NMIs and power failures trigger NMIs Connect pins and 2 to write protect the Pins 2 and 3 EEPROM Connect pins 2 and 3 to enable connected writing to the EEPROM EEPROM write enabled J14 Connect pins 1 and 2 to enable the Nothing connected watchdog timer Do not connect pins 2 watchdog and 3 Normally the watchdog timer is disabled disabled pins 1 and 2 not connected BL1200 Specifications 65 66 Specifications BL1200 C IMEMORY VO AND INTERRUPT VECTORS Appendix C provides detailed information on memory provides an I O map and lists the interrupt vectors BL1200 Memory I O Map and Interru
41. at contains portions of the Dynamic C library is created 1992 Z World Inc Your own copyright notice may also be included on the label to protect your portion of the code Z World grants purchasers of the Dynamic C software and the copyrighted the BL1200 EPROM permission to copy portions of the EPROM library as described above provided that 1 The resulting EPROMs are used only with the BL1200 control lers manufactured by Z World Inc and 2 Z World s copyright notice is placed on all copies of the EPROM Downloading Programs from a Distance In some circumstances there may be a need to download a program to a BL1200 located some distance away This is accomplished via a serial communications link Downloading code under these circumstances requires a monitor program on the BL1200 Once written this program is burned into EPROM It then serves as master controller loading and executing programs and receiving control when the executed program relinquishes control A properly written monitor program gains control whenever the remote BL1200 is reset either by power on by timeout of a watchdog timer or by the reset key To ensure that the controller sending the downloaded code can reset a remotely located 1 1200 install an external hardware reset line via one of the remote BL1200 s RS 485 ports CTS or RXC Con nect the output of the RS 485 receiver to the same reset line as the BL1200 s onboard reset pushbutton swi
42. be much weaker than that needed to cause permanent damage so having the ability to recover from such faults improves the system s reliability under stressful environmental conditions Be especially careful to avoid creating a state in which hitwd is called repeatedly in an endless loop The watchdog then will not time out when it should BL1200 System Development 51 Software bugs that occur only once a week or once a year and cause the program to enter an endless loop are not unusual They are difficult to correct The following three examples illustrate such bugs 1 The stack overflows following a coincidence of events such an interrupt that occurs when a seldom executed but deeply nested piece of code is executing If the seldom executed code is executed for only 10 ms every five minutes and if the interrupts take place only once per hour on average then the program will crash only once or twice per year of continuous operation 2 A multibyte variable is shared between a high level and an interrupt routine Precautions are not taken to prevent the occurrence of interrupts while the high level function is modify ing the multibyte variable Thus the storage of data in the multibyte variable could be interrupted after only one of two bytes have been stored causing the interrupt routine see a mixture of two numbers the old and new that is garbage If one of the incorrectly set variables represents an address to jump to
43. begin flashing 8 Return the board to programming mode Enable header J1 Connect socket 8 on header H2 VCC with a jumper wire to socket 1 on header H3 COMI T H3 i H2 T H1 00000900 190000000 10000000000 9 Skip Step 9 if the BL1200 will be run at 19 200 baud Otherwise connect one end of the 4 jumper wire to socket 7 on H2 GND or socket 10 on header H1 GND For a communications rate of 57 600 28 800 or 9600 baud connect the other end of the wire to socket 3 socket 4 or socket 5 respectively on header input channels 10 11 or I2 10 Press the reset button The LED will blink several times Disable J1 and disconnect the 4 wire BL1200 Sample Projects 97 Read the BL1200 s Input Channels The BL1200 s eight optically isolated input channels can be used to detect mechanical switch closures This project uses the board s own power point VCC and ground GND to trigger one or more of the input channels When read by software the eight inputs appear as a single 8 bit binary word The program displays this binary word as a hexadecimal number in Dynamic C s STDIO window Materials Required e Two 2 inch pieces and one 4 inch piece of insulated solid core 22 gauge jumper wire Program SEEINPUT C provided with Dynamic C BRR e ee e e e e e ke e eee eee
44. bled and a brownout causes an extended stay in the power fail interrupt routine then the watchdog can time out causing a system restart Even if the power is cut off from the board abruptly a certain amount of computing time will remain before the 5 V supply falls below 4 5 V The amount of time depends on the size of the capacitors in the power supply The standard wall transformer provides about 10 ms If the power cable is abruptly removed from the BL1200 then only the capacitors on the board are available and the time 1s reduced to a few hundred microseconds These times can vary considerably depending on the board configuration and the other loads if any drawing from the board s power supply The time interval between detection of a power failure and entry to the user s power fail interrupt routine is approximately 100 us or less if Dynamic C s nonmaskable interrupt communications are not in use It is hard to test power fail interrupt routines presents because the inter rupts are normally disabled Probably the best test method involves leaving messages in battery backed memory to track the execution of the power fail routines If a variable transformer is available to drive the wall transformer then brownouts and other types of power fail conditions can be easily simulated BL1200 Memory I O Map and Interrupt Vectors 75 Jump Vectors Jump vectors are special interrupts that occur in a different way Instead of loading th
45. by the use of watch window commands that examine variables processed by the running program The background task backgnd runs when there is nothing else to do display updates are performed by this task This ensures that the vital high priority tasks are not delayed by the relatively time consuming calls to printf Procedure 1 Once the PC is properly linked to the BL1200 start Dynamic 2 Open DEMO RT Cin the SAMPLES subdirectory 102 Sample Projects BL1200 3 Press to compile and F9 to run DEMO RT C The watch window and STDIO window appear after a few seconds The STDIO window displays output from the five independent tasks Real time kernel demo Sacramento Davis Oakland temp 8 T volume 1005 00 Leave Sacramento intake 1 heater 0 set temperature 56 00 F4 arrows to change San Jose 4 Press F4 to enable the keyboard 5 Change the set temperature by five or six degrees Be patient Your key presses which have low priority must await their turn Notice that the tank temperature displayed near the top of the STDIO window adjusts quickly to the new set temperature The train and liquid intake controller chug along unaffected 6 The set temperature may also be changed with a watch window command Press F4 again to deactivate the keyboard Then type settemp 70 followed by ENTER The watch window processes the command and the value displayed in the STDIO window changes accordingly 7 Pr
46. cket 10 on header H1 GND Connect the other end of the 4 jumper to socket 3 on header H3 grounding input channel 10 The input status byte now reads FE Connecting the wire to one of the other ports grounding it will cause a corresponding change in the hex value displayed Try enabling two of the ports at the same time by adding another ground wire from socket 10 of header H1 or splicing the existing one into two Grounding both 16 and I1 for example produces an input status byte of BD Disconnect the 4 wire s and the 2 wires from the BL1200 10 Press lt Ctrl Z gt to stop the program BL1200 Sample Projects 99 Control the BL1200 s Output Channels Each of the BL1200 s eight output channels can drive an inductive load such as a solenoid or relay For this exercise a simple noninductive load circuit consisting of an LED and a resistor will be used in series With this setup each channel operates as a logic output Power for the test circuit is obtained from the onboard 5 V power point VCC Materials Required A330 Q 4 W resistor and a miniature LED e Program ENOUTPUT C provided with Dynamic C CK e e ee e e e e ke e e eee eee ke ke ke ke e ke ke ke ke ke EnOutput C Repeatedly turns one of the BL1200 s eight output channels on and off KK KK RK KKK RK KKK RRR KKK He He He He He He e He e e He He He He He He He i
47. data for example recording temperature at 1 min intervals Two library functions are available for intermittent operation 34 System Development BL1200 setperiodic int period code Specifies the interval between VOFF pulses from the time date clock A period code of4 signifies 1 second 8 signifies 1 minute and 12 signifies 1 hour e sleep Turns power off until next periodic power on cycle The periodic interrupts depend on the mode set into the battery backed memory of the time date clock in the Epson 72421 chip If a voltage transient upsets the 72421 or if the board s lithium battery goes dead then the board could fail to wake up at the specified time To guard against this kind of failure add an external wake up circuit to replace or supplement the 72421 for critical applications that must run unattended Onboard LED A single LED sits adjacent to the Z180 chip on the BL1200 The LED turns on and remains on whenever the board 18 powered up If an error occurs during startup the LED flashes one of two continuous error message patterns as explained below Pattern Meaning The board has been set for run mode but there is no valid user program in EPROM or in battery backed RAM An attempt was made to write to the EEPROM with jumper J11 in write protect position This message appears only when initializing EEPROM The LED also flashes a distinctive verification pattern four blinks whenever one of t
48. e Projects 101 Test the Real Time Kernel Dynamic C s real time kernel RTK allows the program to be subdivided into prioritized tasks Each task can be treated as a separate program running independently of other tasks The RTK which relies on the system clock executes tasks in order of priority For more information about the real time kernel consult the Dynamic C manuals Materials Required e Program DEMO RT C provided with Dynamic C The five tasks within DEMO RT C are named task 1 task 2 task 4 task 5 and backgnd Tasks 1 and 2 simulate a tank containing 1000 L of liquid A level flag equivalent to a mechanical float switch switches on when the level of liquid falls below a predefined point Task 2 is a control loop Whenever the level in the tank is low task 2 sets an intake flag visible on the screen and always 0 or 1 which opens an intake valve When the temperature falls too low task 2 sets a heater flag also visible on screen turning on the heater The temperature setpoint is the desired temperature of the tank It too is visible Task 4 simulates a train car in transit from Sacramento to San Jose Its output on the screen 15 the moving Task 5 invoked every five clock ticks calls the library routine zunwatch This processes any watch window command entered while the program is running Because tasks 1 2 and 4 all have higher priority than task 5 they will not be delayed
49. e address of the interrupt routine from the interrupt vector jump vectors cause a jump directly to the address of the vector for example 0x66 nonmaskable power failure interrupt which contains a jump instruction to the interrupt routine Since nonmaskable interrupts can be used for Dynamic C communications the interrupt vector for power failure is normally stored just in front of the Dynamic C program A vector may be stored there by the command JUMP_VEC NMI VEC name The Dynamic C communication routines relay to this vector when the NMI 15 caused by a power failure rather than by a serial interrupt Interrupt Priorities Table C 9 lists the interrupt priorities Table C 9 Interrupt Priorities Interrupt Priorities Highest Priority Trap Illegal Instruction NMI Nonmaskable Interrupt SIO Channel SIO Channel B CTC Channel 0 CTC Channel 1 CTC Channel 2 CTC Channel 3 PIO Channel PIO Channel INT 1 expansion bus attention line interrupt INT 2 expansion bus attention line interrupt PRT Timer Channel 0 PRT Timer Channel 1 DMA Channel 0 DMA Channel 1 Clocked Serial I O Asynchronous Serial Port 0 Lowest Priority Asynchronous Serial Port 1 The priority of the SIO CTC and PIO interrupts can be altered through the KIO control register 76 Memory I O Map and Interrupt Vectors BL1200 D EEPROM BL1200 EEPROM 77 EEPROM Parameters The onboard EEP
50. eader H2 to socket 2 on header COM2 Connect one end of a second short jumper wire to socket 7 on H2 GND or socket 10 on header H1 also GND Connect the other end of the wire to socket 7 on header H3 input channel I4 Press the reset button The LED will blink several times indicat ing that the new operating mode has been written to the EEPROM The BL1200 then begins running continuously Disconnect the jumper across header J1 and disconnect the wires connected in Steps 3 and 4 If the Dynamic C EPROM is present on the board the BL1200 executes the program stored in battery backed RAM that is the program last run under Dynamic C If the Dynamic C EPROM has been replaced with a custom EPROM then the 1 1200 executes that program Operation 25 Returning to Programming Mode The BL1200 will remain in run mode until the EEPROM is reprogrammed again Do the following to return the board to programming mode 1 Enable EEPROM reprogramming by connecting pins 1 and 2 of header J1 2 Connect a short insulated jumper wire from socket 8 on header H2 VCC to socket 1 on header COM1 3 Press the reset button The LED will blink several times indicat ing that the new operating mode has been written to the EEPROM 4 Disconnect the jumper from header J1 and disconnect the wire connected in Step 2 Changing Baud Rate on the BL1200 Use the following procedure to change the baud rate at w
51. ector has six pins 56 Troubleshooting BL1200 Dynamic C Will Not Start If Dynamic C will not start an error message on the Dynamic C screen for example Target Not Responding or Communication Error announces acommunication failure Wrong Baud Rate Either Dynamic C s baud rate is not set correctly or the BL1200 s baud rate is not set correctly Both baud rates must be identical The BL1200 baud rate is stored in the EEPROM Chapter 2 described how to change this rate Dynamic C s baud rate is set by the Setup Target command in the SETUP menu Wrong System Clock Speed in EEPROM The EEPROM stores the system clock speed as a word at location 0x108 in multiples of 1200 Hz If this number is incorrect the BL1200 will try to communi cate at the wrong baud rate Wrong Communication Mode Both the PC and the BL1200 must be using the same protocol RS 232 EIA or RS 485 The BL1200 always uses half duplex RS 485 Use Dynamic C s SETUP menu to check and alter the protocol for the PC Wrong COM Port generally has two serial ports COMI and COM2 Specify the one used in the Dynamic C Target Setup menu Use trial and error if necessary Wrong Port BL1200 The BL1200 has two RS 485 serial ports Serial Port 0 must be used for the PC interface as described in Chap ter 2 Wrong Operating Mode Communication with Dynamic C is lost when the BL1200 is in run mode Check header J1 and the connections on
52. ed these resistors terminate and bias the transmission bus maintain ing the line level when no device is driving the bus BL1200 System Development 37 The receiver to Rx is always enabled The line enable 485 enables the driver to Tx which is driven by the PIO on the board Use the following function calls to enable and disable the transmitter SetPIODB 0x80 enable chan 0 driver resPIODB 0x80 disable chan 0 driver SetPIODB 0x40 enable chan 1 driver resPIODB 0x40 disable chan 1 driver Make sure these calls are used Do not manipulate the PIO registers directly This preserves the relationships among the various PIO inputs and outputs When several devices are connected to an RS 485 twisted pair one device is the master device It sends a command to another device and then listens for the response from that device The command contains a device address devices listen but only the device that recognizes the address responds When the master completes its message it releases the bus At some later time the slave enables its driver and responds This delay interval is known as turnaround time See Figure 4 7 Master Turnaround time Slave Figure 4 7 Turnaround Time in Master Slave Communication If the turnaround time is too short the master may not have gotten off the bus before the slave starts to drive the bus A similar problem can occur when the slave g
53. el 14 is disconnected the default condition the board is set for programming mode and Serial Port 0 is initialized for use with Dynamic C Similarly when channels 10 through 2 are all left disconnected again the default condition the BL1200 sets the communi cations baud rate to 19 200 bits per second Inputs 10 through I3 are connected to COMI socket 1 on header and inputs 14 through 7 are connected to COM2 socket 2 on header H3 Any input can be turned on by connecting the appropriate common COMI or line to 5 V socket 8 on header H2 and connecting the input channel to GND socket 7 on header H2 or socket 10 on header Changing Parameters Stored EEPROM Install jumper across header J1 2 Connect the desired input channel For example to change the baud rate to 57 600 28 800 or 9 600 connect 10 or 11 or I2 respectively To switch from programming mode to run mode connect 14 To initialize an EEPROM connect I5 16 Remember that leaving I4 disconnected the default condition switches the board from run mode back to programming mode Likewise leaving I0 11 and I2 all disconnected will return the communications rate to the default setting of 19 200 baud 3 Press the reset button to restart the BL1200 The LED will blink four times indicating that one of the parameters stored in EEPROM has been rewritten 4 Disconnect J1 and any setup wires The BL1200 will automa
54. equired for the EPROM Other clock frequencies and other setups are possible with various tradeoffs among power consumption memory access time and perfor mance A very slow clock e g 2 MHz will decrease power consumption to about 0 3 W It is also possible to switch power on and off intermit tently or to enter and exit sleep mode or System Stop mode periodically under control of the battery backed clock This can further reduce power consumption The cost of course is decreased computing power and slower response time 36 System Development BL1200 Serial Ports The BL1200 has two asynchronous serial ports shown in Figure 4 5 These ports implemented via the Z180 s built in serial communications channels are equipped with half duplex RS 485 drivers 10 H3 2 1 H1 0000000000 00000000 0000000000 0000000000 0000000000 VCC 5 V output GND Channel 1 RS 485 Channel 1 RS 485 12 24Vin GND for power Channel 0 RS 485 Channel 0 RS 485 gt Figure 4 5 BL1200 RS 485 Asynchronous Serial Ports The logical configuration of one of the serial ports appears in Figure 4 6 enable 485 5 Q 485 2200 RS 485 bus i i 485 Rx 5 680 Q Figure 4 6 Configuration of BL1200 RS 485 Serial Ports The 680 Q and 220 resistors are optional They are needed only on the two devices located at the ends of an RS 485 twisted wire pair When install
55. es to the correct sockets on header H2 The BL1200 may be destroyed in an instant if the power supply is connected to the wrong socket A protective diode prevents damage to the BL1200 if the power supply polarity is reversed 18 Getting Started BL1200 2 Check jumpers Ten jumpers on the BL1200 board define the hardware configuration Appendix B lists the jumper settings 3 Establish a serial communications link A PC communicates with the BL1200 via Serial Port 0 on the BL1200 s microprocessor using RS 485 communications protocols There are two options to install the communications link Option 1 RS 232 to RS 485 converter This option with the developer s kit is more expensive than the XP8700 communication board but provides all the necessary programming accessories Use the serial cable to connect the PC s 9 pin or 25 pin RS 232 serial port to a Z World RS 232 to RS 485 converter Either PC serial port COMI COM2 may be used Then connect four wires between the converter and the BL1200 as shown in Figure 2 2 9 pin serial 7 ze Sa serial cable ui PAN bur 22 2 RS 232 to RS 485 converter Figure 2 2 Using Converter to Program BL1200 BL1200 Getting Started 19 Figure 2 3 shows a detailed view of the link between the converter and the BL1200 Two short insulated wires link sockets 3 and 4 on the converter and sockets 3 and 4 on header H2 of the BL1200
56. ess lt Ctrl Z gt to stop the program BL1200 Sample Projects 103 Read the System Clock This routine the contents of the BL1200 s battery backed real time clock to be read and modified Materials Required e Program SETCLOCK C provided with Dynamic C Procedure 1 Once the PC is properly linked to the BL1200 start Dynamic 2 Open SETCLOCK C in the SAMPLES subdirectory 3 Press F3 to compile and F9 to run SETCLOCK C The watch window and STDIO window will appear The time and date currently stored in the clock are displayed in the STDIO window yy mm dd hh mm ss day 92 08 19 21 43 03 wed 4 Press F4 to enable the keyboard 5 Change the value of a field Press R to reset the entire record Be patient The response to key presses is somewhat slow 6 Press Q to quit then ESC 7 Press lt Ctrl Z gt to stop the program 104 Sample Projects BL1200 ArPENDIX BATTERY Appendix G provides information about the onboard lithium battery BL1200 Battery 105 Storage Conditions and Shelf Life The battery on the BL1200 will provide approximately 9 000 hours of backup for the real time clock and static RAM as long as proper storage procedures are followed Boards should be kept sealed in the factory packaging at room temperature until field installation The board should not be exposed to extremes of temperature humidity or contaminants The backup time 15 affected by many factors i
57. eter rete tectae trs 104 Materials Required errem rte 104 PROCEGUIG M 104 Appendix G Battery 105 Storage Conditions and Shelf Life sss 106 Replacing the Lithium Battery esee 106 Battery Cautions S enun pau 107 Index 109 vi Table of Contents BL1200 Tuis MANUAL This manual provides instructions for installing testing configuring and interconnecting the Z World 1 1200 controller Instructions are also provided for using Dynamic C functions Assumptions Assumptions are made regarding the user s knowledge and experience in the following areas Ability to design and engineer the target system that a BL1200 will control e Understanding of the basics of operating a software program and editing files under Windows on a PC Knowledge of the basics of C programming GY Fora full treatment of C refer to the following texts The C Programming Language by Kernighan and Ritchie C A Reference Manual by Harbison and Steel Knowledge of basic Z80 assembly language and architecture Gv For documentation from Zilog refer to the following texts Z180 MPU User s Manual Z180 Serial Communication Controllers Z80 Microprocessor Family User s Manual BL1200 About This Manual vii Terms and Abbreviations Table 1 lists and defines terms and abbreviations that may be used in this manual
58. ets off the bus and the master gets back on the bus to send the next message Use a delay interval equal to about three character transmissions to avoid such problems 38 System Development BL1200 Figure 4 8 illustrates how asynchronous data travel after they are transmit ted Every character begins with a start bit and ends with a stop bit The start bit has the same polarity as 0 and the stop bit has the same polarity asa 1 The state is also the polarity of the line at rest Start bit Stop bit 485 N 485 Figure 4 8 Transmission of Asynchronous Data Letter 0x41 Two special problems can occur when the Z180 s serial ports are used in half duplex mode First there is no direct way to determine when all the characters held in the internal transmitter registers have been completely sent This happens because the serial port becomes ready for the next character when the current character is transferred from the transmitter data register to the transmitter shift register but there is no way to directly tell when the transmitter shift register is empty of the last character sent When all the characters are sent the driver must be disabled but not before and not too long after The best way to determine when a transmis sion is complete is to make the transmitting station listen to its own transmission counting the characters received versus the characters sent This is easil
59. flash at all even when connected to channel O6 the polarity may be reversed Try turning the circuit around connecting the LED at VCC and using the resistor s lead to probe the output channels The call to hv wr in ENOUTPUT C writes an 8 bit hexadecimal value to the output driver Any bits that are 1 in this value will turn on the cor responding output channels bit 7 for O1 bit 0 for O8 As written ENOUTPUT C sends a value of 4 to the driver chip The third bit is a one turning on output channel O6 7 Press F4 to return to Dynamic C s editor Change the assignment to hv datum 50 it writes hex 80 instead of 4 The new line should read hv_datum x80 hex 80 port O1 ON The binary equivalent of hex 80 is 1000 0000 This byte when sent to the output driver turns on output channel O1 8 Press F9 to run the program again 9 Move the LED s wire to each of the output ports verifying that the LED flashes only when connected to output channel O1 socket 1 10 Press F4 again 11 Edit ENOUTPUT C once more this time changing the call to hv datum so it writes hex CF enabling all channels except O3 and O4 12 Press F9 13 Move the free end of the LED resistor circuit from socket to socket Verify that all channels except O3 and O4 sockets 3 and 4 have been enabled 14 Press lt Ctrl Z gt Do not save the modified version of ENOUTPUT 15 Remove the LED resistor circuit from the 0 BL1200 Sampl
60. flat surface that accepts screws BL1200s can also be mounted in modular circuit board holders and attached to DIN rail a mounting system widely used for electrical components and controllers as shown in Figure 1 3 Bus Connectors Modular PC Board Holders Figure 1 3 Mounting BL1200 on DIN Rail A DIN rail is a long metal rail The BL1200 and other add on boards slide snugly into modular plastic printed circuit board holders which then snap onto the rail The circuit holders 75 mm wide are available in multiples of lengths of 11 25 mm 22 5 mm or 45 mm These holders can be snapped end to end to create a tray of almost any length oY Appendix B provides detailed specifications for the BL1200 BL1200 Overview 15 Software Development and Evaluation Tools Dynamic C Z World s Windows based real time C language development system is used to develop software for the BL1200 The host PC down loads the executable code through the BL1200 s RS 485 port to one of the following places e battery backed RAM or ROM written on a separate ROM programmer and then substi tuted for the standard Z World ROM This allows fast in target development and debugging A BL1200 Developer s Kit contains the manual schematics programming cable power supply 128K SRAM RS 232 to RS 485 converter and a Demonstration Board to simulate input output eu Z World s Dynamic C reference manuals provide complete software descri
61. g development e Verify that the BL1200 runs in standalone mode before connecting any expansion boards or I O devices e Verify that the entire system has good low impedance separate grounds for analog and digital signals The BL1200 is often connected between the host PC and another device Any differences in ground potential can cause serious problems that are hard to diagnose e Do not connect analog ground to digital ground anywhere e Verify that the host PC s COM port works by connecting a known good serial device to the COM port Remember that a PC s COM1 COM3 and 2 share interrupts User shells and mouse software in particular often interfere with proper COM port operation For exam ple a mouse running on COMI can preclude running Dynamic C on Use the Z World power supply supplied with the Developer s Kit If another power supply must be used verify that it has enough capacity and filtering to support the BL1200 e Use the Z World cables supplied The most common fault of other cables is their failure to properly assert CTS at the RS 485 port of the BL1200 Without CTS being asserted the BL1200 s RS 485 port will not transmit Assert CTS by either connecting the RTS signal of the PC s COM port or looping back the BL1200 s RTS Check the connections carefully to the converter or the XP8700 card Note that telephone company wiring has four wires with 4 pin RJ 11 connectors whereas the RJ 12 conn
62. he parameters in the EEPROM has been changed see Appendix D The RTSO line of Serial Channel 0 controls the onboard LED The following function can be used to enable and disable the LED without disturbing the operation of the serial port flasher int If k is nonzero the LED is illuminated if 0 the LED is turned off BL1200 System Development 35 Power Conserving Configuration The BL1200 is available with either an 18 432 MHz crystal or a 12 288 MHz crystal A system with the 12 288 MHz crystal though slower consumes less power Table 4 3 BL1200 Power Consumption Configurations PAL U6 Header J6 Crystal Frequency Normal FP0440x 2 3 18 432 MHz Conserving FP0445x 1 2 12 288 MHz The power modes are summarized in Table 4 3 The frequency of the operating clock is half the crystal frequency either 9 216 MHz or 6 144 MHz The power consumption is 0 8 W at 9 216 MHz and 0 4 W at 6 144 MHz If the Z180 s System Stop mode is enabled when the power conserving 12 288 MHz crystal is set up the power consumption drops further to approximately 0 2 W The battery backed time date clock can wake the processor 64 times per second in the System Stop mode When using the standard 18 4432 MHz crystal make sure the EPROM and RAM used are capable of a memory access time no slower than 150 ns When using the power conserving setup a 150 ns access time is required for the RAM and an access time of 200 ns is r
63. header H3 as described in Chapter 2 so that the BL1200 communi cates with Dynamic C at 19 200 bps Wrong Jumper Setting Check headers J1 J5 and J6 since they affect the operating mode and the baud rate Wrong Clock Crystal The baud rates for serial ports 0 and 1 on the BL1200 vary depending on the BL1200 clock frequency If a the clock frequency is not 9 216 MHz 18 432 MHz crystal or 6 144 MHz 12 288 MHz crystal the adjustment in baud rate to communicate with external devices will have to be calculated manually Plug Reversed on RS 232 to RS 485 Converter The serial link will be wired incorrectly if the 10 pin connector on the converter s serial cable is reversed BL1200 Troubleshooting 57 Dynamic C Loses Serial Link Dynamic C will lose its link if the program disables interrupts for more than 50 ms If a communication method is used that is not driven by the nonmaskable interrupt NMI make sure that interrupts are not disabled for more than 50 ms This is not a concern if a communication method driven by NMI is used BL1200 Resets Repeatedly If the watchdog timer is enabled by installing J14 a system reset will occur every 1 6 seconds if the watchdog timer is not hit Dynamic C hits the timer but a user program must include a call to 16 init at the start of the program to make sure the watchdog timer is hit periodically Input Output Problems A strobe is needed to move data in PIO mode
64. hich the BL1200 s RS 485 ports communicate with other devices Make sure the power supply is properly connected at sockets 1 and 2 on header H2 see Figure 3 1 2 Connect pins 1 and 2 on header J1 3 Connect a short insulated jumper wire from socket 8 on header H2 to socket 1 on header COMI the common line for input ports 10 through 4 Connect one end of a second 4 inch jumper wire to socket 7 on H2 GND or socket 10 on header H1 also GND 5 Connect the other end of the 4 inch wire to socket 3 on header 10 socket 4 on I1 or socket 5 on 2 as desired selecting a baud rate of 57 600 bps 28 800 bps or 9600 bps respectively Leave the wire unconnected to select the default baud rate of 19 200 bps 6 With the wires still connected press the board s reset button The LED on the BL1200 board will blink four times indicating that information has been written to the EEPROM 7 Disconnect the jumper across header J1 and disconnect the wires connected in Steps 3 4 and 5 Remember to reset the serial rate in Dynamic C after changing the baud rate of the BL1200 26 Operation BL1200 EPROM Programming EPROMs Dynamic C can be used to create a file for programming an EPROM by selecting the Compile to File option in the COMPILE menu The BL1200 must be connected to the PC running Dynamic C during this step because essential library routines must be uploaded from the Dy
65. i About This Manual BL1200 Programming Abbreviations For convenience this manual uses the following pseudo types uint means unsigned integer ulong means unsigned long These pseudo types are not standard C keywords therefore they will not function in an application unless first declared with typedef or define Pin Number 1 A black square indicates pua fr es pin 1 of all headers 1 o Measurements diagram and graphic measurements are in inches followed by millime ters enclosed in parenthesis Icons Table 3 displays and defines icons that may be used in this manual Table 3 Icons Icon Meaning Refer to see BS Please contact Caution A High Voltage TI D Tip Factory Default BL1200 About This Manual ix X About This Manual BL1200 CHAPTER 1 OVERVIEW Chapter 1 provides an overview and a brief description of the BL1200 features BL1200 Overview 11 BL1200 Overview The BL1200 controller is extremely compact and is capable of handling small control jobs at low cost The BL1200 s rugged design allows it to be used in the harshest industrial environments Figure 1 1 illustrates the BL1200 board layout
66. idering only the bits needed to set the baud rate The clock and baud rates are supplied in units of 1200 Hz Thus a 9 216 MHz clock is expressed by 7680 and 19 200 bps is represented by 16 The function returns 1 if the baud value cannot be derived from the given clock frequency The serial ports appear to the CPU as a set of registers Each port can be accessed directly accessed directly by calling the functions inport and Table 4 4 Z180 Serial Port UART Registers Address Description CNTLAO Control Register A Serial Channel 0 CNTLAl Control Register A Serial Channel 1 CNTLBO Control Register B Serial Channel 0 CNTLB1 Control Register B Serial Channel 1 STATO Status Register Serial Channel 0 5 1 Status Register Serial Channel 1 TDRO Transmit Data Register Serial Channel 0 TDR1 Transmit Data Register Serial Channel 1 RDRO Receive Data Register Serial Channel 0 RDR1 Receive Data Register Serial Channel 1 outport and by using the following symbolic constants in Table 4 4 For example to read and write from channel 20 set char ch ch inport RDRO outport TDRO ch 40 System Development BL1200 Ports may be polled or driven by interrupts The interrupt vectors are OE 8880 vEC 7180 Serial Port 0 10 1 vEC 7180 Serial Port 1 Baud Rates The Z180 s serial ports can generate standard baud rates for crystal frequencies of 6 144 MHz or 9 216 MHz or a frequenc
67. ioPlcAdr12 unsigned addr Specifies the address to be written to the PLCBus using cycles BUSADRO BUSADRI and BUSADR2 PARAMETER addr is broken into three nibbles and one nibble is written in each BUSADRx cycle LIBRARY EZIOPLC LIB EZIOPLC2 LIB EZIOMGPL LIB e void setl6adr int adr Sets the current address for the PLCBus All read and write operations access this address until a new address is set PARAMETER adr is a 16 bit physical address The high order nibble contains the value for the expansion register and the remaining three 4 bit nibbles form 12 bit address the first and last nibbles must be swapped LIBRARY DRIVERS LIB e void setl2adr int adr Sets the current address for the PLCBus All read and write operations access this address until a new address is set PARAMETER adr is a 12 bit physical address three 4 bit nibbles with the first and third nibbles swapped LIBRARY DRIVERS LIB e void eioPlcAdr4 unsigned addr Specifies the address to be written to the PLCBus using only cycle BUSADR2 PARAMETER addr is the nibble corresponding to BUSADR2 LIBRARY EZIOPLC LIB EZIOPLC2 LIB EZIOMGPL LIB 90 PLCBus BL1200 e void set4adr int adr Sets the current address for the PLCBus All read and write operations access this address until a new address is set A 12 bit address may be passed to this function but only the last four bits will be set Call this function only if the firs
68. ister values are output to the bus their values are stored in the shadow registers All interrupts that use the bus save the four shadow registers on the stack Then when exiting the interrupt routine they restore the shadow registers and output the three address registers and the expansion registers to the bus This allows an interrupt routine to access the bus without disturbing the activity of a background routine that also accesses the bus To work reliably bus devices must be designed according to the following rules 1 The device must not rely on critical timing such as a minimum delay between two successive register accesses 2 The device must be capable of being selected and deselected without adversely affecting the internal operation of the controller Allocation of Devices on the Bus 4 Bit Devices Table E 4 provides the address allocations for the registers of 4 bit devices Table E 4 Allocation of Registers A1 A2 A3 Meaning digital output registers 64 registers 64 x 8 2 512 1 bit registers 000j 001j xxxj analog output modules 64 registers digital input registers 128 registers 128 x 42 512 input bits 000j 10xj analog input modules 128 registers 000j 11xj 128 spare registers customer 001j xxxj xxxj 512 spare registers Z World j controlled by board jumper X controlled by PAL 88 PLCBus BL1200 Digital output devices such as relay drivers should be addressed with
69. nal logic circuits are isolated from the inputs An input outside the specified voltage range would likely damage either the load resistor or the optical isolator chip Both are easily replaced Relay Driver Outputs Each of the BL1200 s eight relay driver outputs can sink a DC current of approximately 300 mA at about 50 V Each output includes a protective diode allowing it to drive an inductive load such as a relay coil or a small solenoid Serial Ports The BL1200 has two RS 485 ports that allow serial data to be sent over a pair of twisted wires up to several kilometers at rates as high as 57 600 bps BL1200 Overview 13 number of BL1200 boards can be connected together on the same twisted pair and this same wire pair may be shared with other devices such as a PC When several devices share an RS 485 bus one device acts as master and the others serve as slaves If a standard 2 wire RS 485 bus is augmented with two additional wires providing 24 V and ground the resulting 4 wire bus can provide power and communications to a network of BL1200s distributed throughout a building or factory Battery Backed Clock The BL1200 s time date clock accurate to approximately second per day can be used to sequence events or to record a history of events A small onboard lithium battery powers the clock whenever external power shuts off Under normal operating conditions this battery can power the clock for approximately 10 years
70. namic C EPROM and linked to the resulting file The output is a binary file optionally an Intel hex format file that can be used to build an application EPROM The application EPROM is then programmed with an EPROM program mer that reads either a binary image or the Intel hex format file The resulting application EPROM can then replace the EPROM that came with the BL1200 Whenever the Dynamic C EPROM is replaced by a custom EPROM the BL1200 ignores the program in battery backed RAM in favor of the program stored in EPROM Choosing EPROMs Socket U2 can accommodate several different types of EPROMs includ ing the following 226 32K 28 pins 22 64 28 pins 2000 128 32 pins When using a 28 pin EPROM four pin positions at one end of the socket are left empty as shown In Figure 3 3 J3 J4 J3 J4 Me u1 28 32 lt lt A 02 2 U6 U6 SRAM 35 SRAM q Ls Figure 3 3 Placement of 28 pin and 32 pin EPROMs on BL1200 Remember to set jumpers J2 13 and on the BL1200 board according to the settings in Appendix B to indicate the sizes of EPROM and SRAM chips installed BL1200 Operation 27 Copyrights The Dynamic C library is copyrighted Place a label containing the following copyright notice on the EPROM whenever an EPROM th
71. ncluding the amount of time the board is unpowered size of static RAM temperature humidity and exposure to contaminants including dust and chemicals Protection against environmental extremes will help maximize battery life Replacing the Lithium Battery Use the following steps to replace the battery 1 Locate the three pins on the bottom side of the printed circuit board that secure it to the board 2 Carefully de solder the pins and remove the battery Use a solder sucker to clean up the holes 3 Install the new battery and solder it to the board Use only a Panasonic BR2325 1GM or equivalent 106 Battery BL1200 Battery Cautions Caution English There is a danger of explosion if battery is incorrectly replaced Replace only with the same or equivalent type recommended by the manufacturer Dispose of used batteries according to the manufacturer s instructions Warnung German Explosionsgefahr durch falsches Einsetzen oder Behandein der Batterie Nur durch gleichen Typ oder vom Hersteller empfohlenen Ersatztyp ersetzen Entsorgung der gebrauchten Batterien gem b den Anweisungen des Herstellers Attention French Il y a danger d explosion si la remplacement de la batterie est incorrect Remplacez uniquement avec une batterie du m me type ou d un type quivalent recommand par le fabricant Mettez au rebut les batteries usag es conform ment aux instructions du fabricant Cuidado Spanish Peligro de e
72. ng errors 59 wrong Cables 56 wrong COM port 56 communication Dy attic C eene 76 RS 485 sente 14 senal 16 serial ports menmete 13 connectors 26 pin PLCBus pin assignments 84 constants initialization 73 sconti 43 GTS T 43 enable oe etui 43 prescaler 46 ceti 46 1 siete 43 D DOX DTX iter 85 Data Carrier Detect 42 data format mode bits 44 DCDDO emt 43 DEMO 102 DIN rail 15 62 110 Index DIP relays eec 84 divide 70 eerie es 46 DMA idee eene tite tette tn 44 downloading programs 28 downloading software 28 46 drivers software expansion bus 89 expansion bus 8 bit 92 nte 89 DRIVERS LIB 89 21 communication 76 serial options 22 will not start s 57 E E e edem 81 GG WE ncaenmibpnmmiepnmeis 81 EEPROM baudrate ione 78 changing stored parameters 80 clock speed 2 5 n 78 constants recette tes 73 initialization 78 79 80 input channels 79 library routines 81 operati
73. ng mode 78 programming 78 TUM estero sri ERES 78 programming error 80 write protect 14 35 78 81 writes WROTE 2n 81 wrong clock frequency 57 0 43 bit RE dens 43 1 12 90 91 1 91 2 91 1 90 1200 ENOUTPUT C usen 100 EPROM 16 27 73 CHOOSING 27 28 27 OPUONS rennes 27 programming 27 Exp A D12 84 expansion boards TOS Cb 90 expansion bus 14 84 85 86 87 88 89 8 bit drivers 92 tese Er 88 GEVICES epe eere 88 89 digital inputs 89 functions 90 91 92 93 rules for devices 88 software drivers 89 expansion register 88 EZIOBL17 LIB 89 EZIOLGPL LIB 89 EZIOMGPL LIB 89 2 eee 89 89 EZIOTGPL LIB 89 F EEEE A E 43 44 35 framing error
74. nt i main hv enb enable driver 1 1 hv_datum x00 hex 00 all OFF hv wr hv datum write byte to driver for i 0 1 lt 10000 i hitwd short pause hv_datum x04 hex 04 port O6 ON hv wr hv datum write byte to driver for i 0 i lt 30000 i hitwd longer pause Procedure 1 Once the PC is properly linked to the BL1200 start Dynamic 2 Open ENOUTPUT C in the SAMPLES subdirectory 3 Wire wrap or solder together the resistor and the LED making a load circuit 3 to 4 long as shown G JC 10 H3 1 8 H2 1 10 H1 1 0000000000 00000000 0000000000 180000000 j GND 08 06 04 O2 vec 07 05 03 01 100 Sample Projects BL1200 4 Connect the resistor end of the load circuit to socket 8 of header H2 VCC 5 Press F3 to compile and F9 to run ENOUTPUT C The watch window will appear after a few seconds There is no STDIO window because the program does not write to or read from STDIO i e there are no calls to printf getchar etc 6 Touch the free end of the LED resistor circuit to output channel O1 on header H1 the right most socket socket 1 Nothing happens The LED remains unlit Now touch the lead to each of the other seven channels on H1 The only response is at channel O6 socket 6 With the load circuit connected there the LED flashes about twice a second If the LED does not
75. ntrol 44 ASCI Contro Register B see nette t tee sert ee tu ita 45 Tmne Date ete to erhebt e 48 Watchdog Timer ss sass ci tiit erret th ern 51 Using the Watchdog Timer 5 oerte emt 51 53 Z World Technical Manuals 53 Zilog Technical Manuals eene 53 Hitachi Technical iro nme Ha 53 Specifications for Various Integrated Circuits 54 Appendix A Troubleshooting 55 CUE OE TMG BORSA mE eU 56 Dynamic C Will Not Start ur ete rete o ir 57 Dynamic C Loses Serial Link eese 58 1200 Resets 0 0 58 Input Output Problems 2 20 58 Power Supply Problems eter eret etre 58 Blown Out 5841 Driver 58 Common Programming Errors 59 iv Table of Contents BL1200 Appendix B Specifications 61 Hardware Dimensions 2 62 Jumper and Header Specifications sees 64 Appendix C Memory I O Map and Interrupt Vectors 7 BL1200 Memory eH TOU TRE 68 Execution inet eerte Cero a PU HERR 69 Memory Access T 1mes ue se rte gb 69 Memory Map ero nier eid iren 70 Initialized Memory 73 Interr pt Vectors IHE DRE FRE RIRs 73 Nonmaskable Interr pts 74 Power Fail Inter
76. on rate port and protocol are all selected by choosing Serial Options from Dynamic C s OPTIONS menu The BL1200 s default communication rate is 19 200 baud However the Dynamic C software shipped by Z World may be initialized for a different rate To begin adjust the communications rate to 19 200 baud Make sure that the PC serial port used to connect the serial cable COMI or COMO is the one selected in the Dynamic C OPTIONS menu Select the 1 stop bit protocol Running a Sample Program As a final test of the communications link run the sample program PFLASH C in Dynamic C SAMPLES directory This program flashes the LED that sits adjacent to the Z180 chip on the BL1200 board Prior to running this test be sure to set the communications parameters in Dynamic C so that the PC and the BL1200 are handshaking properly 1 Compile the program by pressing F3 or by choosing Compile from the COMPILE menu Dynamic C compiles and downloads the program 2 Run the program by pressing F9 or by choosing Run from the RUN menu The LED on the BL1200 will begin flashing continuously 4 Press lt Cirl Z gt to stop execution of the program 5 If needed press F9 to restart execution of the program 22 Getting Started BL1200 Charter 3 BL1200 OPERATION Chapter 3 describes how to use the BL1200 with a focus on how to set the run and programming modes and how to burn a custom program on EPROM BL1200 Operation 23 Ope
77. ous modes Item no 03 3033 01 Z80 Assembly Language Programming good reference on assembly language Item no 03 0002 02 out of print 7180 CPU Technical Manual Description of Z180 processor and internal peripherals When interfacing the Z180 with Z80 style peripherals consult also the Z80 CPU Technical Manual Item no 03 0029 01 and the Z80 CPU Programming Manual Item no 03 0012 03 Hitachi Technical Manuals Order from Hitachi America Ltd San Jose California HD64180 8 Bit Microprocessor Manual Covers the HD64180Z which is functionally identical to the Zilog Z180 chip used in the BL1200 Item no U77 BL1200 System Development 53 HD64180 8 Bit Microprocessor Programming Manual Contains detailed description of each operation code Item no U92 Specifications for Various Integrated Circuits Specifications 5841A high current high voltage driver Sprague Electric Company Worcester Mass tel 508 853 5000 Specifications 24C04 EEPROM Microchip Inc Chandler Ariz tel 602 963 7373 Note Xicor of Milpitas Calif tel 408 432 8888 has similar parts and parts of larger capacity 54 System Development BL1200 A TROUBLESHOOTING Appendix A provides procedures for troubleshooting system hardware and software BL1200 Troubleshooting 55 Out of the Box Check the items listed below before starting development Rechecking may help to solve problems found durin
78. pt Vectors 67 BL1200 Memory The BL1200 s memory is divided into two segments corresponding to the memory chip sockets U1 for EPROM and U2 for SRAM Both the EPROM chip and the SRAM chip may have 28 or 32 pins Devices as large as 512K 8 bit bytes 32 pin package may be installed The static RAM is backed up during power off periods by a lithium battery A program is run entirely from battery backed RAM while it is being developed Once the program is burned into EPROM the battery backed RAM is normally used only to store data Therefore most applications should work with 32K 8 bit bytes RAM when running from EPROM Additional RAM say 128K 8 bit bytes is required to develop applica tions In general 32K of RAM will allow programs up to 20K 2000 C statements to be developed and 128K of RAM will allow programs as large as 116K 10 000 C statements to be developed Set headers 12 13 and 14 to correspond to the sizes of the EPROM and SRAM chips according to the details in Appendix B Registers in the I O space are accessed by calling the Dynamic C library functions inport and outport as in these two lines of sample code data value inport CNTLAO outport CNTLAO data value The library routines IBIT ISET and IRES can also be used to set and clear bits in the I O registers 68 Memory I O Map and Interrupt Vectors BL1200 Execution Times Table C 1 provides the execution times for a BL1200 with a 9 216 MHz clock and
79. ptions and programming instructions Typical Applications Machine Control Many small machines are controlled using contact closure inputs and solenoid outputs The BL1200 s optically isolated input channels can receive mechanical contact closures and pushbutton signals from a human operator Its outputs can operate solenoid valves and small actuators AC devices can be switched on and off by adding an expansion board contain ing relays such as Z World s XP8400 board or by driving a relay with the BL1200 s high current outputs The high current outputs can also operate solid state relay modules that switch 120 V or 240 V AC Distributed Control In certain types of factory control and in many manufacturing tests con trol must be provided at different locations throughout a building with centralized control from a single location A number of BL1200s can be networked together with an RS 485 communication bus to solve this type of problem For example several BL1200s can be used to control several separate pieces of equipment that test finished products Each test station running autonomously periodically sends statistics to a central station Software is downloaded to the distributed stations over the serial network As another example a network of up to 256 BL1200s is used for a distrib uted building access control system Each BL1200 controls its building entry site Each BL1200 reports to and is controlled by a central sta
80. qualify components to operate within a range of parameters that is different from the manufacturer s recommended range This strategy is believed to be more economical and effective Additional testing or burn in of an individual unit is available by special arrangement Trademarks Dynamic C isa registered trademark of Z World e Windows isa registered trademark of Microsoft Corporation PLCBus 13 a trademark of Z World Z World Inc Telephone 530 757 3737 2900 Spafford Street Facsimile 530 753 5141 Davis California 95616 6800 Web Site http www zworld com USA E Mail zworld zworld com TABLE CONTENTS About This Manual vii Chapter 1 Overview 11 eee 12 lovi e 13 Optically Isolated 13 Relay Driver Outputs tt entries 13 Serial Ports tin emanates 13 Battery Backed Clock eet then tremere pte 14 Switching Power Supply 4 0n eee odd 14 Expansion Bst 14 MGM OLY 14 15 Software Development and Evaluation Tools 16 Typical AppliCatiOnS nr itt eere teer 16 MagcInne Conttol rtt eere n teo enc eds 16 Distributed Control rte teret tenent 16 Chapter 2 Getting Started 17 Initial BLI200 E ERE 18 Parts
81. r inverts this line This bit is essentially a 1 bit output port without other side effects CKAID Disable This bit controls the function assigned to the multiplexed pin 1 TENDO 1 TENDO a DMA function and 0 CKAI external clock I O for Channel 1 serial port 44 System Development BL1200 TE Transmitter Enable This bit controls the transmitter 1 transmitter enabled 0 transmitter disabled When this bit is cleared the processor aborts the operation in progress but does not disturb TDR or TDRE RE Receiver Enable This bit controls the receiver 1 enabled 0 disabled When this bit is cleared the processor aborts the operation in progress but does not disturb or the error flags MPE Multiprocessor Enable This bit 1 enabled 0 disabled controls multiprocessor communica tion mode which uses an extra bit for selective communication when a number of processors share a common serial bus This bit has effect only when MP in control register B is set to 1 When this bit is 1 only bytes with the MP bit on will be detected Others are ignored All bytes received are processed if this bit is 0 Ignored bytes do not affect the error flags or ASCI Control Register B Control Register B for each channel configures multiprocessor mode parity and baud rate selection ENTERI 03 028 CTS R W R W R W R W SS Source Speed Select Coupled with the
82. rating Modes When starting up after a hard reset the BL1200 assumes one of several modes depending on whether the Dynamic C EPROM is installed and whether the program jumper across header J1 has been enabled The flowchart in Figure 3 1 describes the various actions the BL1200 may take at startup Begin from hardware reset Valid program in EPROM Jumper J1 enabled YES Run user program Read input channels for mode and baud rate Write control byte to EEPROM Enter mode specified by control byte in EEPROM Figure 3 1 BL1200 Activity at Startup 24 Operation BL1200 Run Mode Once a program has been written and debugged the program can run from RAM or an EPROM may be burned Before running a program from battery backed RAM or from a custom EPROM first switch the BL1200 from programming mode to run mode Reprogram the EEPROM to do this according to the following procedure 1 BL1200 Make sure that the BL1200 s power supply is connected properly at sockets 1 and 2 on header H2 as shown in Figure 3 2 D AC 0000000000 00000000 0000000000 00000000001 0000000000 H2 H1 24 GND Figure 3 2 BL1200 Power Supply Connections at Header H2 Connect pins 1 and 2 of header J1 to enable EEPROM repro gramming Connect a short insulated jumper wire from socket 8 on h
83. releases the pushbutton When power is no longer needed the program calls the function powerdown turning the power supply off until another external event reenables the power supply This logic can be used to create a battery powered instrument that turns off automatically conserving the battery after a certain period of inactivity 2 Using the clock enable power at regular intervals for a short period of time The available periods are 1 second minute and 1 hour Pins 2 and 3 of header J8 must be connected the factory setting is for pins 3 4 to be connected When the power supply is switched on the power must remain on for at least 60 ms As long as the power supply is turned on for only 60 ms of each second the power consumption will be decreased by a factor of approximately 15 to 1 If the power supply is switched on once a minute the ratio will be 900 to 1 Powering on once every hour reduces the ratio to 54 000 to 1 Now apply this to a practical situation If the BL1200 is powered continu ously by a 9 V 500 mA h battery the board can remain on only 1 5 hours With the power enabled only briefly one time per second the battery life can be extended to approximately one day Powering on briefly once a minute extends battery life to approximately two months and powering on only once an hour extends the battery life to approximately 10 years This type of power usage is convenient for applications that involve collection of
84. respec tively These are the two RS 485 channels The other two wires for ground and 5 V link sockets 7 and 8 on the converter and sockets 7 and 8 on header H2 respectively as shown 8 1 Converter GND 485 5 V 485 10 Dn 0000000000 0000000000 0000000000 H3 H2 H1 24V GND Figure 2 3 Detail View of RS 232 to RS 485 Converter Connections Option 2 XP8700 RS 232 communication board This option is less expensive but lacks the accessories provided with the Developer s Kit Use the serial cable to connect the PC s 9 pin or 25 pin RS 232 serial port to the XP8700 Either PC serial port COMI or COM2 may be used The serial cable may be connected to the RJ 12 jack or to the header on the XP8700 depending on the plug on the serial cable 20 Getting Started BL1200 The XP8700 is then connected to the BL1200 s PLCBus port as shown in Figure 2 4 pem 0 e 9r m MA J 4d gt PAL Ala 7180 2 EEPROM 6 uhe SCC2691 UA
85. resses 00 3F Internal 2180 I O Registers Address 00 Name CNTLAO CNTLAI Description Control Register A Serial Channel 0 Control Register A Serial Channel 1 CNTLBO Control Register B Serial Channel 0 CNTLBI Control Register B Serial Channel 1 STATO Status Register Serial Channel 0 Status Serial Channel 1 Timer Control Register SAROL Source Address Channel 0 least SAROH DMA Source Address Channel 0 most continued 70 Memory I O Map and Interrupt Vectors BL1200 Table C 2 BL1200 Addresses 00 3F Internal 2180 I O Registers Address Name concluded Description 27 BCROH DMA Byte Count Register Channel 0 most MARIL DMA Memory Address Register Channel 1 least MARIH DMA Memory Address Register Channel 1 most MARIB DMA Memory Address Register Channel 1 extra bits IARIL I O Address Register Channel 1 least DMA I O Address Register Channel 1 most BCRIL DMA Byte Count Register Channel 1 least BCRIH DMA Byte Count Register Channel 1 most DMA Status Register Reserved CBAR MMU Common Bank Area Register 3B 3D Reserved OMCR Operation Mode Control Register I O Control Register Table C 3 BL1200 Addresses 40 43 PIO Registers Address Name Description Table C 4 BL1200 Addresses 80 81 LCD Interface Address Name Description 80 LCD control register 81 LCD data register BL1200 Memor
86. rupts ipsis ie 74 J mp Vectors 76 Interrupt Priorities o neret eer eterne Es EEEE E e pna 76 Appendix D EEPROM 77 EEPROM zoe rr eto reri eb rio e bebes 78 Operating Mod rte teet rptu eot d eee Posee 78 Baud Rate 78 Clock n 78 EEPROM Channels ie Hed Rr etc 79 Changing Parameters Stored in EEPROM 80 Error Messages sert Ptr RE en eR 80 Library npe Ce rne 81 Appendix E PLCBus 83 84 5 Allocation of Devices on the Bus sse 88 4 e 88 5 0 89 Expansion Bus SOF Wate Ee vo Eos 89 Appendix F Sample Projects 95 Run a Program from Battery Backed RAM esses 96 Materials oe DR er e EC RE 96 Proc dure s oo esr ordner 96 Read the BL1200 s Input Channels eene 98 Materials 6 eiie teen tet reiten etit 98 Proc dure o EODD 98 BL1200 Table of Contents v Control BL1200 s Output Channels 100 Materials Required ite reto OR en ERR 100 0 100 Test the Real Time iet 102 Materials Required ge eerte Revo 102 0 re rb P D 102 Read the System rt
87. s 0 and 1 The strobe lines are connected to J12 Use Mode 3 for static input Mode 1 may appear to work but will be erratic because the strobe line floats Power Supply Problems The input resistor must be changed when input voltages exceeding 28 V are used If the external power supply does not have sufficient capacity an addi tional load such as an LED can trigger a power fail interrupt initiating a hardware reset The reset triggers the load to be turned off but then the computer restarts and turns the load back on The oscillation can be corrected by increasing the size of the power supply Blown Out 5841 Driver Chip The 5841 driver chip may blow if SUB floats Protect the chip by install ing a filter capacitor in the line connecting K to the power supply if this wire is long If K is not connected the 5841 chip will blow if an inductive load is con nected The circuit will then be enable so be sure to plan for this situation 58 Troubleshooting BL1200 Common Programming Errors Table A 1 Ranges of Dynamic C Function Types int 32 768 215 to 432 767 25 1 long int 2 147 483 648 22 to 2147483647 23 1 float 6 805646 x 1038 to 6 805646 x 1038 char 0 to 255 e Values for constants or variables out of range Counting up from or down to one instead of zero In the software world ordinal series often begin or terminate with zero not one e Confusing
88. s are provided for reading the time date clock e int tm rd struct tm t Reads the time date clock and returns zero if no error occurs Returns if the clock is not working or is not installed long clock Reads the 72421 timer and returns time as seconds since January 1 1980 The sample program PLCLK C illustrates a keyboard interface to display and set the time date clock manually The following function allows the clock to be set from within a program e int tm wr struct tm t Writes the content of the structure to the clock Returns O if structure is written normally Returns 1 if the clock is failing or is not installed BL1200 System Development 49 The following functions allow seconds from January 1 1980 to be converted to the time structure ulong mktime struct tm t Converts time expressed as the structure t into time expressed as seconds since January 1 1980 Does not access the timer chip e int mktm struct tm t ulong time Converts time expressed as seconds time into time expressed as the structure t Does not access the timer chip 50 System Development BL1200 Watchdog Timer The watchdog timer is a reliability feature If the two pins on header J14 are connected enabling the watchdog a timer starts running This timer must be reset frequently by calling the library function hitwd If the watchdog timer runs for 1 6 seconds without being hit it is considered to have
89. s of the address are the same as the address in the previous call to set24adr LIBRARY DRIVERS LIB e int read24data0 long address Sets the current PLCBus address using the 24 bit address then reads eight bits of data from the PLCBus with a BUSRDO cycle RETURN VALUE PLCBus data in lower eight bits upper bits 0 LIBRARY DRIVERS LIB e int read8data0 long address Sets the last eight bits of the current PLCBus address using address bits 16 23 then reads eight bits of data from the PLCBus with a BUSRDO cycle PARAMETER address bits 16 23 are read RETURN VALUE PLCBus data in lower eight bits upper bits 0 LIBRARY DRIVERS LIB e void write24data long address char data Sets the current PLCBus address using the 24 bit address then writes eight bits of data to the PLCBus PARAMETERS address is 24 bit address to write to data is data to write to the PLCBus LIBRARY DRIVERS LIB e void write8data long address char data Sets the last eight bits of the current PLCBus address using address bits 16 23 then writes eight bits of data to the PLCBus PARAMETERS address bits 16 23 are the address of the PLCBus to write data is data to write to the PLCBus LIBRARY DRIVERS LIB BL1200 PLCBus 93 94 PLCBus BL1200 SAMPLE PROJECTS The demonstrations or projects in Appendix F explore BL1200 fea tures subsystems and sample programs BL1200 Sample Projects 95
90. t eight bits of the address are the same as the address in the previous call to set12adr PARAMETER adr contains the last four bits bits 8 11 of the physical address LIBRARY DRIVERS LIB char 6102080620 Reads the data on the PLCBus in the BUSADRO cycle RETURN VALUE the byte read on the PLCBus in the BUSADRO cycle LIBRARY EZIOPLC LIB EZIOPLC2 LIB EZIOMGPL LIB char 1068601 Reads the data on the PLCBus in the BUSADRI cycle RETURN VALUE the byte read on the PLCBus in the BUSADRI cycle LIBRARY EZIOPLC LIB EZIOPLC2 LIB EZIOMGPL LIB e char 610268622 Reads the data on the PLCBus in the BUSADR2 cycle RETURN VALUE the byte read on the PLCBus in the BUSADR2 cycle LIBRARY EZIOPLC LIB EZIOPLC2 LIB EZIOMGPL LIB e char 2088120868 int adr Sets the current PLCBus address using the 12 bit adr then reads four bits of data from the PLCBus with BUSADRO cycle RETURN VALUE PLCBus data in the lower four bits the upper bits are undefined LIBRARY DRIVERS LIB BL1200 PLCBus 91 char read4data int adr Sets the last four bits of the current PLCBus address using adr bits 8 11 then reads four bits of data from the bus with BUSADRO cycle PARAMETER adr bits 8 11 specifies the address to read RETURN VALUE PLCBus data in the lower four bits the upper bits are undefined LIBRARY DRIVERS LIB void eioWriteWR char ch Writes information to the PLCBus during the BUSWR cycle P
91. tch The BL1200 s memory map and the format for downloaded files must be correct in a successful monitor program that can GS load software files Both topics are reviewed in Z World s Dynamic C Technical Reference manual 28 Operation BL1200 CuaPreR 4 SYSTEM DEVELOPMENT Chapter 4 provides the following information to develop the BL1200 for specific uses BL1200 Optically Isolated Input Relay Driver Output Intermittent Operation Onboard LED Power Conserving Configuration Serial Ports Watchdog Timer References System Development 29 Optically Isolated Input The BL1200 board has eight optically isolated input channels Channels 10 through 13 in Figure 4 1 share a single common line COM1 channels 14 through 17 share a second common line COM2 H3 H2 H1 10 1 8 1 10 1 0000000000 00000000 0000000000 00000000 12000000000 COMI for 10 13 COM for 14 17 l6 12 10 7 16 13 1 Figure 4 1 BL1200 Optically Isolated Input Channels The circuit diagram in Figure 4 2 shows a typical optically isolated input 5V 10 kQ Input to PIO AAA 4 3 Figure 4 2 Typical BL1200 Optically Isolated Input When current flows through an input to the common or vice versa one of the LEDs inside the optical isolator chip illuminates a phototransistor This causes current to flow through the 10 KQ p
92. ters are mostly binary coded decimal BCD numbers making up the date and time The following notes refer to these registers Table 4 7 Epson 72421 Registers Address Bit 3 Bit 2 Bit 1 Bit 0 Meaning Range Seconds Tens of secs Minutes Tens of mins Hours Tens of hrs Days Tens of days Months Tens of mos Years Tens of years Weekday REG D INTR 05 1 TO STND MASK REGE 05FH TEST 12 24 STOP RSET REGF 48 System Development BL1200 For 24 hour mode set the 12 24 bit to 1 Otherwise the clock runs in 12 hour mode and the AM PM bit will be 1 for PM When using the 24 hour mode mask out the AM PM bit For day of the week the numbers 0 6 represent Sunday through Saturday Leap year is automatically taken into account To set the clock for 1990 set year to 90 Functions to read and write the time date clock and to change or reset the time and date are included the Dynamic C library DRIVERS LIB The following structure is used to hold the date and time struct tm byte tm sec seconds 0 59 byte tm min minutes 0 59 byte tm hour 24 hour time 0 23 byte tm mday day of month 1 31 byte tm mon month 1 12 byte tm year eg 90 1990 101 2001 byte tm wday day of week 0 6 tm val Sunday is 0 Time can also be expressed as seconds since January 1 1980 midnight December 31 1979 It takes approximately 600 us to read the clock chip The following function
93. tically use the new mode or baud rate specified for the next restart The board will continue to operate with the new setting until the EEPROM is changed Follow the above procedures to change both the baud rate and the operat ing mode First perform the procedure for one of these parameters then repeat the procedure for the other parameter Error Messages The LED next to the Z180 chip may flash a continuous dot dash pattern if there is an error in setting up the board Two patterns are possible The board is set to run mode but there is no valid user program in EPROM or in battery backed RAM An attempt was made to write to the EEPROM with J11 in write protect position This message appears only when initializing EEPROM 80 EEPROM BL1200 Remember that EEPROM addresses above 100 may write protected by a jumper across header J11 Library Routines The following library routines can be used to read and write the EEPROM int ee rd int address int ee wr int address byte data The function ee rd returns a data value or if a hardware failure occurred The function ee wr returns 1 if a hardware failure occurred 2 if an attempt was made to write to the upper 256 bytes with the protection jumper header J11 installed or 0 to indicate a successful write A write protection violation does not wear out the EEPROM These routines each require about 2 5 ms to execute They are not re entrant that is only one
94. timed out The BL1200 is then forced into a hardware reset condition for 50 ms Once the hardware resets the board resumes operation as if the power had just been turned on Several Dynamic C library functions allow a power on reset to be distin guished from a watchdog reset The following functions are associated with the watchdog timer void hitwd void Each time this function is called it hits the watchdog timer postponing an automatic hardware reset for another 1 6 seconds e int wderror void Returns 0 if the previous hardware reset was caused by power on or by pushing the reset button Returns a nonzero value if the previous reset was caused by timeout of the watchdog timer Using the Watchdog Timer The watchdog is hit frequently when a Dynamic C program is being debugged However if a jumper is connected across header J14 and a program that contains no watchdog hits starts running a reset will take place after 1 6 seconds and Dynamic C will report a loss of communica tions The watchdog timer s purpose is to enable recovery from a fault condition such an endless loop or invalid microprocessor state Such a fault condition can be caused by an electrical transient or by a soft ware bug An electrical transient can generate a state internal to the micro processor that would be impossible during normal operation A transient strong enough to upset the state of the microprocessor or erase part of the memory can
95. tion 16 Overview BL1200 2 GETTING STARTED Chapter 2 provides instructions for connecting the BL1200 to host PC and running a sample program BL1200 Getting Started 17 Initial BL1200 Setup Parts Required 24 V unregulated DC power supply Programming cable e RS 485 to RS 232 converter or XP8700 expansion board The necessary parts are supplied with the developer s kit Connecting the BL1200 to a Host PC 1 Connect the power supply to the BL1200 The BL1200 normally operates from a 24 V unregulated DC power supply but will operate satisfactorily with a 12 V unregulated power supply However if the BL1200 is to be connected to one or more accessory boards that include 24 V relays the 12 V supply will not operate the 24 V relays The 24 V DC wall transformer provided in Z World s Developer s Kit is recommended Connect the two leads from the DC power supply or wall transformer to sockets 1 and 2 on header H2 as shown in Figure 2 1 Use a small screwdriver to push down the small plastic lever above the socket to insert a lead into one of the connection sockets Do not power up the power supply until the remaining steps have been completed 10 1 8 1 10 1 0000000000 00000000 0000000000 10000000006 2 H1 24V GND Figure 2 1 BI1200 Power Supply Connections at Header H2 Be careful to connect the power supply wir
96. ullup resistor pulling the PIO chip s output low NEC 2506 4 photocouplers are used although other devices may be substituted if desired A current of 0 2 mA is suffi cient to trigger the photocoupler The current should not exceed 80 mA so as not to overheat the photocoupler Normally such a high current would not be encountered without first blowing the 0 5 W 4 3 resistor To avoid overheating the resistor do not apply more than 50 V The resistor supplied will accommodate input of 2 V to 50 V at 0 2 mA to 12 mA The input can be either AC or DC If AC is used the output turns off briefly each time the AC voltage crosses O V An AC on off state can be detected by sampling the logic waveform every few milliseconds 30 System Development BL1200 The common line can be either plus or minus For example the common line can be 24 V when contact closures are being monitored and the contacts connect the inputs to ground For TTL logic input the common line would be 5 V and the TTL drivers would then pull the inputs to ground sinking 1 mA Relay Driver Output The BL1200 has eight high current output ports These ports located on header H1 are well suited for driving relays and solenoids The ports can also be used as logic outputs with the addition of a pullup resistor Fig ure 4 3 shows the relay driver outputs H3 H2 H1 1001000 Damn 00000000001 100000000
97. vice Then read or write from to the register The register is selected by placing its address on the bus Each device recog nizes its own address and latches itself internally A typical device has three internal latches corresponding to the three address bytes The first is latched when a matching BUSADRO is de tected The second is latched when the first is latched and a matching BUSADRI is detected The third is latched if the first two are latched and a matching BUSADR 2 is detected If 4 bit addressing is used then there are three 4 bit address nibbles giving 12 bit addresses In addition a special register address is reserved for address expansion This address if ever used would provide an additional four bits of addressing when using the 4 bit convention If eight data lines are used then the addressing possibilities of the bus become much greater more than 256 million addresses according to the conventions established for the bus 86 PLCBus BL1200 Place an address on the bus by writing bytes to BUSADRO BUSADRI and BUSADR 2 in succession Since 4 bit and 8 bit addressing modes must coexist the lower four bits of the first address byte written to BUSADRO identify addressing categories and distinguish 4 bit and 8 bit modes from each other x There are 16 address categories as listed in Table E 3 An indicates that the address bit may be a 1 or a 0 Table E 3 First Level PLCBus Address Coding
98. xplosi n si la pila es instalada incorrectamente Reemplace solamente con una similar o de tipo equivalente a la que el fabricante recomienda Deshagase de las pilas usadas de acuerdo con las instrucciones del fabricante Waarschuwing Dutch Explosiegevaar indien de batterij niet goed wordt vervagen Vervanging alleen door een zelfde of equivalent type als aanbevolen door de fabrikant Gebruikte batterijen afvoeren als door de fabrikant wordt aangegeven Varning Swedish Explosionsf ra vid felaktigt batteribyte Anv nd samma batterityp eller en likv rdigt typ som rekommenderas av fabrikanten Kassera anv nt batteri enligt fabrikantens instruktion BL1200 Battery 107 108 Battery BL1200 INDEX Sym bols battery CAUTIONS oo eect tees 107 HINT VEC voc uenerunt 73 replacing eene 106 2 2 2 1 76 shelf 63 106 c ea 85 battery backed RAM 16 CTS 43 46 baudrates 41 46 47 57 63 42 changing s s s 26 IRDX enemies 85 bidirectional data lines 85 IRT SO rnense 44 BL1200 85 board 1 12 IMIRX aee htt ees 85 default communication rate 22 assignment 59 dimensions 62 4 bit bus operations 85 86 88 features 2 13 5 x 3 addressing mode 87 mounting 15 62 5841 driver chip
99. y I O Map and Interrupt Vectors 71 Table 5 BL1200 Addresses 0 Expansion Bus Address Name Description CO BUSRDO Primary bus read address 4 C8 BUSADRO Write bus address byte 0 CE BUSWR Write bus OB BUSEXP Address of bus expansion register Table C 6 BL1200 Addresses 100 10F 72421 Real Time Clock Registers Address Bit 3 Bit 2 Bit 1 Bit 0 Meaning Range 100 S8 54 52 51 Seconds 0 9 101 S40 S20 S10 10 seconds 0 5 102 M8 M4 M2 MI Minutes 0 9 103 M40 M20 M10 10 minutes 0 5 104 H8 H4 H2 Hours 0 9 105 AM PM 0 H10 10 hours 0 2 106 D8 D4 D2 D1 Days 0 9 107 D20 D10 10 days 0 3 108 M8 M4 M2 1 Months 0 9 109 M10 10 months 0 1 10A Y8 Y4 Y2 Y1 Years 0 9 10B Y80 Y40 Y20 Y10 10 years 0 9 10C W4 W2 Wi week days 0 6 10D 30 IRQ BUSY HOLD Register D FLG 10 INTR MASK Register E STND 10 STOP RSET Register F 72 Memory I O Map and Interrupt Vectors BL1200 Initialized Memory Locations Table C 7 lists the constants that are initialized at startup Table C 7 Constants Initialized at Setup CLOCKSPEED Integer containing the clock speed read in units of 1200 Hz from the EEPROM at startup BAUDCODE Integer containing the baud rate in units of 1200 baud as read from the EEPROM at startup JUMPERS Byte read from the PIB port of the PIO at startup Interrupt Vectors Table C 8 presents a suggested interrupt vector map Most of these interrupt vectors c
100. y done with the BL1200 as the serial port s receive channel is always connected to the RS 485 bus The second problem involves determining how to time out the turnaround delay without using a valuable resource such as a timer or a program loop which would waste valuable computing time The receiving device can do this by sending several Oxff characters with the driver enable off The driver can be enabled without sending any spurious data once the start bit from the last character clears the transmitter shift register This is because all the data bits and the stop bit are 1s The only time delay necessary is a program loop to time out the length of the start bit after the data register becomes empty for the last time This time delay is one tenth the length of a full character time delay At typical baud rates it will be of the order of 20 us to 100 us BL1200 System Development 39 Direct Programming of the Serial Ports The Z180 technical manuals listed in the References provide more detailed information to help use the serial ports extensively or to use synchronous communication Z World provides two low level utility functions to get started int sysclock int z180baud int clock int baud The function sysclock returns the clock frequency in units of 1200 Hz as read from the EEPROM The EEPROM stores the clock frequency at memory location 108H The function z180baud returns the byte to be stored in CNTLBO CNTLBI cons
101. y that is a simple multiple or fraction of these for example 3 072 MHz 4 608 MHz 6 144 MHz 9 216 MHz 12 288 MHz Normally the crystal on the BL1200 board is stamped with a number that is twice the clock frequency Driving the Serial Ports Each of the Z180 s independent full duplex asynchronous serial channels has its own baud rate generator For either or both channels the baud rate can be obtained from an external clock or divided down from the micro processor clock One of the Z180 s internal DMA controllers can be used in conjunction with the internal serial ports The serial ports have an optional multiprocessor communications feature When enabled an extra bit is included in the transmitted character where the parity bit would normally go The receiving Z180s can be pro grammed to ignore all characters received except those with the extra multiprocessing bit enabled This provides a 1 byte attention message that can be used to wake up a processor without the processor having to intelligently monitor all traffic on a shared communications link Figure 4 9 shows Serial Channel 0 Serial Channel 1 is similar but modem control lines RTS1 and DCDO are not available Five of the seven registers shown are directly accessible as internal I O registers Microprocessor Internal Bus TXAO Shift Register In RTSO CTso CNTLAO Baud Rate Generator CNTLBO DES sm Figure 4 9 BL1200 Serial
102. y tricky to use because it cannot be disabled while leaving receive interrupts on For most designs it is suggested that the DCDO line be connected directly to ground removing it from consideration ASCI Status Registers A status register for each channel provides information about the state of each channel and allows interrupts to be enabled and disabled STATO 04H R W R W STATI 05H R W R W DCDO0 Data Carrier Detect This bit echoes the state of the DCDO input pin for Serial Channel 0 However when the input to the pin switches from high to low the data bit switches low only after STATO has been read The receiver resets as long 42 System Development BL1200 as the input pin is held high This function is not generally useful because an interrupt is requested as long as DCDO is a 1 This forces the program mer to disable the receiver interrupts to avoid endless interrupts A better design would cause an interrupt only when the state of the pin changes This pin is tied to ground TIE Transmitter Interrupt Enable This bit masks the transmitter interrupt If set to 1 an interrupt is re quested whenever TDRE is 1 The interrupt is not edge triggered This bit must be set to 0 when you want to stop sending Otherwise interrupts will be requested continuously as soon as the transmitter data register is empty TDRE Transmitter Data Register Empty A means that the channel is ready to accept another character
103. ystem Development 43 RDREF Receiver Data Register Full This bit is set when data are transferred from the receiver shift register to the receiver data register The bit is set even when one of the error flags is set in which case defective data is still loaded to RDR The bit is cleared when the receiver data register is read when the DCDO input pin is high and by RESET and ASCI Control Register A Control Register affects various aspects of the asynchronous channel operation Seu 0080 5 wee we Tee wem woo R W R W R W R W R W R W R W R W CNTLAI 01H wee oo CKA1D ii MOD1 MODO R W R W R W R W R W R W R W MOD0 MOD2 Data Format Mode Bits MODO controls stop bits 0 1 stop bit 1 2 stop bits If 2 stop bits are expected then 2 stop bits must be supplied MODI controls parity 0 parity disabled 1 parity enabled See PEO in control registers B for even odd parity control MOD2 controls data bits 0 7 data bits 1 8 data bits MPBR EFR Multiprocessor Bit Receive Error Flag Reset Reads and writes on this bit are unrelated Storing a byte when this bit is 0 clears all the error flags OVRN FE PE Reading this bit obtains the value of the MPB bit for the last read operation when multiprocessor mode is enabled RTSO Request to Send Channel 0 Store a 1 in this bit to set the RTSO line from the Z180 high The output driver furthe

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