OpenTroller DX1
Contents
1. FTDI website http www ftdichip com 2 3 2 Download Required Files e Arduino Integrated Development Environment IDE A custom version of the Arduino IDE is required to support the OpenTroller DX1 to provide support for the ATMEGA1284P microcontroller and external libraries used by the firmware The customized IDE is available under the Downloads section of the BrewTroller website htto www brewtroller com Extract the ZIP file to a location on your hard drive e Firmware Source The firmware source code for your target application ie BrewTroller or FermTroller is available under the Downloads section of the BrewTroller website http www brewtroller com There are often multiple versions of each firmware application available for download o Stable This is the current version recommended for production systems Start with this release for a new system o Testing This is a feature frozen release of the development firmware that is in the process of moving to stable Often users are encouraged to download and test this release to help identify any bugs prior to the release being moved to Stable It is important to start with Stable first to ensure your system is working properly before installing a Testing release o Development Trunk This is the current release still under development It is recommended for developers only Extract the ZIP to a location on your hard drive 2 32. MAY APPEAR IN THIS MANUAL INCLUDING THE PRODUCTS AND SOFTWARE DESCRIBED IN IT Products and corporate names appearing in this manual may or may not be registered trademarks or copyrights of their respective companies and are used only for identification or explanation and to the owners benefit without intent to infringe Contents LL A A 4 Lab ST T NN 4 L Openlroler DAT Fete iii as 4 to PETN SPP 5 BANNE 5 Z QUERES a GN vea 5 Zab CT Na 3 2 2 Connecting LCD Display and Encoder Sold separately ss 6 2 5 Instale perading Fir NAS ii AAA 8 2 COMME CEG I ME DGIC a A Wn Mw Y YNO SN ado en 10 2 35 Connecnno R45 ue ii AAA 11 200 CONNECTE IPS A A A tte ie tee 12 JP NNN 14 0 Des 15 3 VTA DRA e 16 ONA 16 32 ETH RABIN 17 gt BERN NN 17 4 BED CiO PN 17 TN 17 56 CEN 18 4 Mechanical Specifications asia 21 5S Electrical and Environmental SPECIACA MON Sic Na 21 O FNP DO HER a PRP 22 1 Overview OpenTroller is a series of open source programmable controllers developed and manufactured by Open Source Control Systems OpenTroller BX1 The smallest and least expensive model in the OpenTroller series The BX1 is sold as an assembled printed circuit board PCB The BX1 features include 6x 12VDC Sourced Outputs 1 output supporting hardware controlled high frequency PWM 1 Wire bus interface 12C bus interface RS 485 bus interface and USB virtual serial port interface OpenTroller EX1 Include
3. 3 Select Hardware Profile Note The following provides generic instructions not specific to either Ferm Troller or Brew Iroller firmware Your firmware download may contain multiple hardware profiles for the OpenTroller DX1 Refer to the specific firmware documentation for more details regarding selecting a hardware profile In the HWProfiles folder of the firmware source open the OpenTroller DX1 subfolder and copy the HWProfile h file to the root folder of the firmware source ie Ferm Troller or Brew Troller depending on the firmware used You will replace the HWProfile h included in the root folder of the firmware source 2 3 4 Configure and Upload Note The following provides generic instructions not specific to either FermTroller or Brew Iroller firmware Refer to the specific firmware documentation for more details regarding available compile options Launch the Arduino executable from the Arduino IDE folder extracted previously select Open from the File menu browse to the folder where you extracted the firmware source and open the BrewTroller ode or FermTroller ode as appropriate Select the Sanguino w ATMEGA1284P from the Board menu under Tools Select the serial port for the device from the Serial Port menu under Tools Review the Config h tab for compile options if necessary refer to firmware documentation Select Upload to I O Board from the File menu 2 4 C
4. NNECT OPENTROLLER DX1 TO AC POWER OR DC POWER SUPPLIES GREATER THAN 12VDC 2 2 Connecting LCD Display and Encoder Sold separately The OpenTroller DX1 can be connected to a 20x4 character LCD and Encoder via the OpenTroller Display Module connected to the 12C port Connect the 5 pin polarized locking 12C cable into the OpenTroller s 12C Port Connector X4 Connect the other end to the 12C port on the display module Connect the encoder to the encoder port of the display module and then connect the display module to the LCD using the 16 pin connector Refer to the following examples L 2 bat Y s dl 1 LARA A AU D dd NL a SRGROR88B PD y dg Ge F lt ES FONO o Soe sd gt li lt A 2 3 Installing Upgrading Firmware Multiple firmware solutions are available for the OpenTroller platform to support specific applications The latest stable release is always recommended for production systems however the following list identifies the minimum versions required to support the OpenTroller DX1 e BrewTroller 2 5 Build 917 e FermTroller TBD 2 3 1 Connect to PC A mini B USB cable is required to connect the Open Troller DX1 board to your PC Mac for firmware upgrading The OpenTroller DX1 uses a FTDI FT232RL module that installs as a Virtual COM Port VCP device Drivers are usually available within current versions of available Operating Systems If necessary you may download drivers form the
5. R5485 Device ni ns 40 OND aoe ox dus 3 LM 1 F mta i i je a 4 Si mm Brie 2 6 Connecting Outputs The outputs on the OpenTroller DX1 provide up to 100mA 12V per channel Important The OpenTroller DX1 does not provide any back EMF protection when used with standard mechanical relays You must install a reverse protection diode onto the relay coil terminals to prevent noise and potential damage to the OpenTroller DX1 2 6 1 Solid State Relay Example To connect devices such as a solid state relay refer to the diagram below Connect the OpenTroller output to the positive input terminal of the SSR Connect the negative input terminal of the SSR to your power supply ground E TEL 9 8 B gt OCOCCOLECSO inp i EME i 3 riaa mi h EM Uun Cas Clee 0 a fe Cm OG a e Ta Va See BE LEE LLE mi LP EE TE a EE HETE TE Tl 460040050 000000000 6 2 6 2 2 Way Motorized Ball Valve Example 12VDC l2VDC 12VDC Hopen 12V 12V ED meme me de mu au let tani Fe Tu ZA cy o RR hai LD o RR gt 4 6 nn ei u EU im Ti l as Uwm WE pm ag a a 3 AA TE TETTE TT pa jeoghejey 2 7 Analog Inputs Any device that provides an analog 0 5V DC signal can be used as a volume sensor Volume sensors can be connected to the controller using the 6 pole analog input screw terminal block The following diagram shows a typical connection using a Freescale MPX5010 pres
6. TE open source control systems Open Troller DX1 User Manual Document Revision 1 0 July 2 2012 2012 Open Source Control Systems Inc All Rights Reserved Product warranty or service will not be extended if 1 the product is repaired modified or altered unless such repair modification of alteration is authorized in writing by Open Source Control Systems Inc OSCSYS or 2 the serial number of the product is defaced or missing OSCSYS PROVIDES THIS MANUAL AS IS WITHOUT WARRANTY OF ANY KIND AND MAKES NO OTHER REPRESENTATIONS OR WARRANTIES EITHER EXPRESS OR IMPLIED AS TO FITNESS FOR PURPOSE MERCHANTABILITY OR OTHERWISE IN RESPECT OF THE PRODUCT IN NO EVENT SHALL OSCSYS ITS DIRECTORS OFFICERS EMPLOYEES OR AGENTS BE LIABLE FOR ANY DIRECT INDIRECT SPECIAL INCIDENTAL OR CONSEOUENTIAL DAMAGES INCLUDING DAMAGES FOR LOSS OF PROFITS LOSS OF BUSINESS LOSS OF USE OR DATA INTERRUPTION OF BUSINESS AND THE LIKE WHETHER SUCH DAMAGES ARE INCURRED BY THE PERSON TO WHOM THIS WARRANTY EXTENDS OR A THIRD PARTY EVEN IF OSCSYS HAS BEEN ADVISED OF THE POSSIBILITY OF SUCH DAMAGES ARISING FROM ANY DEFECT OR ERROR IN THIS MANUAL OR PRODUCT SPECIFICATIONS AND INFORMATION CONTAINED IN THIS MANUAL ARE FURNISHED FOR INFORMATIONAL USE ONLY AND ARE SUBJECT TO CHANGE AT ANY TIME WITHOUT NOTICE AND SHOULD NOT BE CONSTRUED AS A COMMITMENT BY OSCSYS OSCSYS ASSUMES NO RESPONSIBILITY OR LIABILITY FOR ANY ERRORS OR INACCURACIES THAT
7. ernet module 3 5 Jumpers 3 5 1 Auto Reset Allows automatic reset of board via serial port DTR for uploading firmware during microcontroller boot process May be disconnected to avoid resets caused by serial port activation when not uploading firmware 3 5 2 RS485 Termination This jumper needs to be connected if the OpenTroller DX1 is the first or last device on the RS485 bus 3 6 Connections 3 6 1 3 6 2 0mo0000000000000000 3 6 3 O O O O O O Oo O O O O O O O O Power Connector O O Output Terminals oe O GND 12VDC Ground Output 1 Output 2 Output 3 Output 4 Output 5 Ground Output 6 Output 7 Output 8 Output 9 Ground Output 10 Output 11 Output 12 Output 13 Output 14 Ground External Relay Board Connector Ground 12V Output 1 Output 2 Output 3 Output 4 Output 5 Output 6 Output 7 Output 8 Output 9 Output 10 Output 11 Output 12 Output 13 Output 14 3 6 4 RS485 Terminals RS485 Termination COM B 3 6 5 1 Wire Connector 1 Wire 9 O O GND 1H SU 3 6 6 I2C Communications Port 17 18 19 DANS Sat al COM GND 1Wire 5V SDA SCL N C 12VDC GND 3 6 7 3 6 8 Digital Inputs BD0o0o0oo Analog Inputs BD0o0o0oo NR GI gt Oe RENDE COM Input 1 Input 2 Input 3 Input 4 Input 5 DV Analog 1 Analog 2 Analog 3 Analog 4 Ground 4 Mechanical Specifications 0000000000000 4 53 0000000000000 5 Electr
8. ical and Environmental Specifications Main Power Input 12VDC tg ee ic UN TES Regulated 5V supply referenced to PC ground Level Power Supply External Loads from Main Unregulated 12V supply on connector I2CLCD Power Supply Maximum current 1A Logic Level Communication DVDC Ports Outputs 12VDC Sourced 150mA per channel Analog Inputs 0 5VDC Temperature 0 to 55 C Relative Humidity 20 to 80 relative humidity non condensing 6 Appendix Warranty Open Source Control Systems Inc OSCSYS warrants that this hardware product is in good working condition according to its specifications at the time of shipment for a period of 90 days from the date it was shipped from OSCSYS Should the product in OSCSYS s opinion malfunction within the warranty period OSCSYS will repair or replace the product without charge Any replaced parts become the property of OSCSYS This warranty does not apply to the software component of a product or to a product which has been damaged due to accident misuse abuse improper installation usage not in accordance with product specifications and instructions natural or personal disaster or unauthorized alterations repairs or modifications All warranties for this product expressed or implied are limited to 90 days from the date of purchase and no warranties expressed or implied will apply after that period All warranties for this product expressed or implied shall extend only to the or
9. iginal purchaser The liability of Open Source Control Systems Inc in respect of any defective product will be limited to the repair or replacement of such product Open Source Control Systems Inc may use new or equivalent to new replacement parts Open Source Control Systems Inc makes no other representations or warranties as to fitness for purpose merchantability or otherwise in respect of the product No other representations warranties or conditions shall be implied by statute or otherwise In no event shall Open Source Control Systems Inc be responsible or liable for any damages arising a _ from the use of the product b from the loss of use of the product c from the loss of revenue or profit resulting from the use of the product or d as a result of any event circumstance action or abuse beyond the control of Open Source Control Systems Inc whether such damages be direct indirect conseguential special or otherwise and whether such damages are incurred by the person to whom this warranty extends or a third party
10. onnecting 1 Wire Devices The OpenTroller provides a 1 Wire device bus to interface to temperature sensors and other IO devices The 1 Wire network uses a single shared data line to communicate with many devices Each 1 Wire device has a unique 48 bit address that is used to when sending and receiving data to individual network nodes The JP4 connector provides access to the 1 Wire bus A constant 5VDC VCC connection is provided in addition to the data and ground pins The recommended topology for 1 Wire networks is a bus A single cable should connect from the Open Troller to the first device with the smallest length stub for each device lt 1m The second deviceis connected via a cable from the first device and so on Open Source Control Systems sells a series of M12 cables and splitters that are perfect for connecting 1 Wire networks For more information visit www oscsys com D518B2O DS18B20 1 GND ror ud A ae ys er ser ala e F de 1 A PEO dri AG MC ONS amp Y 43 AM exe ess EAR S1 50014 E ll F 2 5 Connecting RS485 The OpenTroller provides an RS485 serial bus to interface with other IO devices RS485 uses a differential pair of lines A and B for communication Connect the COM A and B terminals to the same terminals on the external IO board When connecting more than two devices a daisy chain or bus topology is recommended as illustrated below R5485 Device R5485 Device
11. s all the features of the BX1 but ships as an assembled unit complete with a wall mountable enclosure with 20x4 Character LCD and Encoder and optional Ethernet interface OpenTroller DX1 Features DIN Rail mountable enclosure 14x 12VDC Sourced Outputs 6 Outputs supporting hardware controlled high frequency PWM 4x 5VDC Analog Inputs 5x 12VDC Digital Inputs Dedicated E Stop Input 1 Wire bus interface I2C bus interface RS 485 bus interface USB virtual serial port interface and optional Ethernet interface 1 1 Safety Information Integration of the OpenTroller DX1 into a control system requires electrical knowledge It is solely the installer s responsibility to assure that the system is configured in a manner consistent with applicable safety requirements Open Source Control Systems Inc does not control how this board is integrated into the control system and cannot be responsible for guaranteeing the safety of your system This device is not guaranteed to be fail safe For example the microcontroller could fail leaving an output active The system into which the device is installed should provide fail safe protection and emergency stop capability If the device is to be used with dangerous voltages care must be taken to prevent an operator or installer from coming into contact with these voltages An enclosure that allows for modest ventilation but prevents intrusion by operator s hands and foreign objects should be utilized with
12. sure sensor PLOOS IS GND Fee RT PE a 2 8 Digital Inputs The OpenTroller DX1 has five opto isolated digital inputs Screw Terminals JP10 A 12VDC signal to a digital input is required to activate an input All digital inputs share a common DC ground which must be supplied via the COM terminal on JP10 The following schematic shows the typical connection for input switches san m ay ploos is ik aa Ground Float or other Switch 12V 3 OpenTroller DX1 Reference 3 1 Layout La T 1005 15 RE 5 E b aj ed grum SU Al nn A4 Wr sml E Stop Header 10 Ethernet Reset Power Input Terminals 11 OpenTroller Reset Output Terminals 12 Analog Inputs External Relay Board Connector 13 Digital Inputs Auto Reset Enable Disable 14 1 Wire Connector USB Connector 15 RS485 Termination OpenTroller Heartbeat 16 RS485 Connector Power Light 17 _ Ethernet Connector pl rd Ethernet Heartbeat 18 12C Expansion Port 3 2 ETH_Reset Button Used to restart the embedded Ethernet module 3 3 BT Reset Button Used to restart reboot the firmware 3 4 LED Indicators 3 4 1 Power Indicates power is connected to controller 3 4 2 OpenTroller Heatbeat Indicates proper operation of the controllers firmware The heartbeat indicator should toggle on off every 750ms 3 4 3 Ethernet Heartbeat Indicates proper operation of embedded Eth
13. this board 1 2 OpenTroller DX1 Features Atmel 8 bit AVR RISC based microcontroller with 128KB flash 4KB EEPROM and 16KB SRAM 14 Transistor based sourced 12V DC Outputs 4 5V DC Analog Inputs 5 12V DC Digital Inputs 1 Dedicated E Stop Input I2C port for connection to expansion modules RS485 Communications port USB Communications port 1 Wire Communications port DIN Rail Mountable Case 1 3 Package Contents Open Troller DX1 Device 1 4 Before You Proceed Please review all safety and connection information before attempting to connect and power on your Open Troller DX1 Open Source Control Systems Inc is not responsible for damage caused to boards by improper connections lf you have any questions please do not hesitate to contact support You can find phone numbers and contact forms on our website http www oscsys com 2 Quick Start Guide 2 1 Connecting Power Power is supplied to the Open roller DX1 via the power connection JP2 The OpenTroller DX1 requires a 12V DC power supply of at least 500mA Additional devices such as relay boards will increase the power supply requirements A 3A or greater power supply is recommended to ensure external device support It is recommended to measure the power supply output with a voltmeter prior to connecting it to the OpenTroller DX1 Damage caused by connecting the OpenTroller DX1 to improper power supply voltages will not be covered under warranty WARNING NEVER CO
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