Digi BL1000 User manual

BL1100

C-Programmable Controller

User’s Manual

019–0010 • 041015–E

Z-World, Inc.

2900 Spafford Street

Davis, California 95616-6800

USA

Telephone:

Facsimile:

Web Site:

E-Mail:

(530) 757-3737

(530) 753-5141

http://www.zworld.com

zworld@zworld.com

BL1100 User’s Manual

Part Number 019-0010

•

041015-E • Printed in U.S.A.

•

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 CRITI-

CAL COMPONENTS IN LIFE-SUPPORT DEVICES OR SYSTEMS

UNLESS A SPECIFIC WRITTEN AGREEMENT REGARDING SUCH

INTENDED USE IS ENTERED INTO BETWEEN THE CUSTOMER

AND Z-WORLD PRIOR TO USE. Life-support devices or systems are

devices or systems intended for surgical implantation into the body or to

sustain life, and whose failure to perform, when properly used in accor-

dance 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

responsibility of the system designer to incorporate redundant protective

mechanisms appropriate to the risk involved.

Trademarks

• Dynamic C

®

is a registered trademark of Z-World

• Windows

®

is a registered trademark of Microsoft Corporation

• PLCBus

™

is a trademark of Z-World

• Hayes Smart Modem

®

is a registered trademark of Hayes Microcom-

puter Products, Inc.

Table of Contents



 iiiBL1100

TABLE OF CONTENTS

About This Manual ix

Chapter 1: Overview 13

Overview..............................................................................................14

Features................................................................................................15

Standard Models ..................................................................................17

Options and Upgrades.....................................................................17

Expansion Boards ...........................................................................18

Development and Evaluation Tools .....................................................19

Developer’s Kit ...............................................................................19

Software ..........................................................................................19

Chapter 2: Getting Started 21

Developer’s Kit Packing List...............................................................22

Connecting BL1100 to a Host PC........................................................22

Factory-Default RS-232 Programming ...........................................22

Establishing Communication with the BL1100 ...................................24

Running a Sample Program .................................................................24

Chapter 3: System Development 25

Operating Modes .................................................................................26

Programming Options .....................................................................27

Run Mode........................................................................................30

Switching Between Run and Program Mode ..................................31

Memory................................................................................................32

EPROM...........................................................................................32

Programming EPROM..................................................................33

SRAM .............................................................................................33

Chapter 4: Subystems 35

Interface Overview...............................................................................36

Power-Supervisor Integrated Circuit ...................................................37

Digital Interfaces..................................................................................38

Zilog KIO Interface.........................................................................38

KIO Command Register ...............................................................39

iv



 Table of Contents BL1100

PIO Interface ...................................................................................40

Using PIO Ports ............................................................................42

PIA Parallel Port ...........................................................................44

Counter/Timer Circuit (CTC)..........................................................44

Timer Control Word......................................................................46

High-Current/High-Voltage Driver .................................................48

Liquid Crystal Display Interface .....................................................50

Serial Communication..........................................................................52

RS-232 Communication ..................................................................54

Modem Communication ...............................................................54

XMODEM File Transfer ..............................................................54

RS-485 Communication ..................................................................55

Developing an RS-485 Network...................................................55

Hardware Connection ...................................................................56

Direct Programming Using Serial Ports...............................................57

Attainable Baud Rates.....................................................................59

Z180 Serial Ports ............................................................................60

Asynchronous Serial Communication Interface...................................62

ASCI Status Registers .....................................................................62

ASCI Control Register A ................................................................64

ASCI Control Register B ................................................................65

SIO Serial Ports ...................................................................................67

Programming the SIO in Asynchronous Mode ...............................70

Chapter 5: Analog Section 73

Analog Inputs.......................................................................................74

Signal Conditioning ........................................................................74

Configuration 4 .......................................................................... 75

Configuration 5 .......................................................................... 75

Installing Components ....................................................................76

A/D Conversion ...................................................................................84

Sources of Error ..............................................................................84

Onboard Temperature Sensor..........................................................85

Analog Output......................................................................................87

Chapter 6: Software Reference 89

Supplied Software................................................................................90

Digital Interfaces..................................................................................91

KIO Counter/Timer Circuit (CTC) .................................................91

High-Current/High-Voltage Driver .................................................92

Liquid Crystal Display Interface .....................................................93

A/D Converter......................................................................................94

Temperature Measurements ..........................................................94

High-Speed Sampling .....................................................................95

Table of Contents



 vBL1100

D/A Converter ......................................................................................96

Miscellaneous Drivers .........................................................................96

Time/Date Clock .............................................................................96

Time/Date Functions.....................................................................96

Watchdog Timer ..............................................................................97

Appendix A: Troubleshooting 99

Out of the Box....................................................................................100

Dynamic C Will Not Start ..................................................................100

Dynamic C Loses Serial Link ............................................................101

BL1100 Repeatedly Resets ................................................................101

PIO Problems.....................................................................................101

Power-Supply Problems.....................................................................101

Blown-Out 5841 Driver Chip ............................................................102

Common Programming Errors ...........................................................102

Appendix B: Specifications 103

Electrical and Mechanical Specifications ..........................................104

BL1100 Mechanical Dimensions ..................................................105

Jumper and Header Specifications.....................................................106

Wago Connector Signals ...............................................................107

LCD Interface ...............................................................................108

Serial Communication Signals ......................................................108

PIO Parallel Port and Other Lines ................................................109

BL1100 Expansion Bus.................................................................109

Jumper Configurations ..................................................................110

Appendix C: Memory, I/O Map, and Interrupt Vectors 113

BL1100 Memory................................................................................114

Physical Memory .......................................................................... 114

Memory Management ................................................................... 114

How Dynamic C Uses the MMU ..................................................116

Control over Memory Mapping .................................................... 118

Extended Memory Code ...............................................................118

Extended Memory Data ................................................................119

Execution Timing .......................................................................... 119

Memory-Access Timing ................................................................120

Memory Map .....................................................................................122

Time/Date Clock ................................................................................126

Initialized Memory Locations .......................................................127

Interrupt Vectors ................................................................................127

Nonmaskable Interrupts .....................................................................129

Power-Fail Interrupts ....................................................................129

vi



 Table of Contents BL1100

Jump Vectors ......................................................................................130

Interrupt Priorities..............................................................................131

Appendix D: EEPROM 133

Parameters..........................................................................................134

Library Routines ................................................................................135

Appendix E: Power Management 137

Power Consumption ...........................................................................138

Intermittent Operation........................................................................139

Appendix F: Opto 22 Support 141

Appendix G: Sample Analog Applications 149

Semiconductor Temperature Sensor ..................................................150

Thermocouple ....................................................................................151

4–20 mA Loop ...................................................................................152

Appendix H: PLCBus 153

Overview............................................................................................154

Allocation of Devices on the Bus ......................................................158

4-Bit Devices ................................................................................158

8-Bit Devices ................................................................................159

Expansion Bus Software ....................................................................159

Appendix I: Simulated PLCBus Connection 165

PIO Port Connections ........................................................................166

Standard Z-World Expansion Boards............................................166

Software Drivers ................................................................................167

Using Expansion Boards with PIO 1 Port A .................................167

General-Purpose Drivers ............................................................167

Relay Expansion Board Drivers .................................................168

D/A Converter Expansion Board Drivers ...................................169

Appendix J: Standalone Operation 171

Reliability...........................................................................................173

Program Life .................................................................................173

Speed.............................................................................................174

Data Space ....................................................................................174

Cost ...............................................................................................174

Ease ...............................................................................................174

Remote Downloading ........................................................................174

Table of Contents



 viiBL1100

Appendix K: BL1100 Expansion Boards 179

Introduction........................................................................................180

Installation .........................................................................................180

Address Mapping for Multiple Cards ...........................................182

Subsystems.........................................................................................183

Digital I/O .....................................................................................185

Programmable Peripheral Interface (PPI)...................................185

Port A ....................................................................................... 186

Port B ....................................................................................... 186

Port C ....................................................................................... 186

Operating Modes ........................................................................189

Mode 0 ..................................................................................... 189

Mode 1 ..................................................................................... 189

Mode 2 ..................................................................................... 189

TTL Input Buffer ........................................................................189

Pulse Width Measurement.............................................................190

Clocks .........................................................................................193

Other Information .......................................................................193

Analog Multiplexer .......................................................................194

Instrumentation Amplifier .............................................................195

A/D Converter...............................................................................196

DGL96 ..........................................................................................199

Software .............................................................................................200

IOEXPAND.LIB ...........................................................................200

96IO.LIB.......................................................................................205

Sample Programs ..........................................................................207

Pulse Width Measurement ..........................................................207

Other Sample Programs ..............................................................209

PWM PAL Equations ....................................................................210

Board Layouts....................................................................................211

I/O Map..............................................................................................216

Jumper and Header Specifications.....................................................220

ADC, DGL, and MUX Expansion Board Signals.........................220

DGL96 Expansion Board Signals .................................................221

Jumper Configurations ..................................................................222

Appendix L: Backup Battery 223

Battery Life and Storage Conditions..................................................224

Replacing Soldered Lithium Battery..................................................224

Battery Cautions ................................................................................225

Index 227

Schematics

viii s Table of Contents BL1100

About This Manual



 ixBL1100

ABOUT THIS MANUAL

This manual provides instructions for installing, testing, configuring, and

interconnecting any of the Dynamic C programmable controllers in the

BL1100 series. (The BL1100 was previously called the Little Giant.)

The term “BL1100” will be used generically throughout this manual when

referring to any controller in the BL1100 series. Where information

applies to a specific controller, the model number will be specified.

Models currently covered by this manual include the BL1100, BL1110,

and BL1120.

Instructions to get started using Dynamic C software programming

functions as well as complete C and Dynamic C references and program-

ming resources are referenced when necessary.

Assumptions

Assumptions are made regarding the user's knowledge and experience in

the following areas:

• Ability to design and engineer a target system that a BL1100 will

control.

• Understanding of the basics of operating a software program and

editing files under Windows on a PC.

• Knowledge of the basics of C programming.

For a 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.

For documentation from Zilog, refer to the following texts.

Z180 MPU User's Manual

Z180 Serial Communication Controllers

Z80 Microprocessor Family User's Manual



BL1100x s About This Manual

Acronyms

Table 1 lists and defines the acronyms that may be used in this manual.

Icons

Table 2 displays and defines icons that may be used in this manual.

Table 2. Icons

Icon Meaning Icon Meaning

$

Refer to or see

!

Note

(

Please contact

7L

S

Tip

Caution

High Voltage

)'

Factory Default

Table 1. Acronyms

Acronym Meaning

EPROM Erasable Programmable Read-Only Memory

EEPROM Electronically Erasable Programmable Read-Only Memory

LCD Liquid Crystal Display

LED Light-Emitting Diode

NMI Nonmaskable Interrupt

PIO Parallel Input/Output Circuit

(Individually Programmable Input/Output)

PRT Programmable Reload Timer

RAM Random Access Memory

RTC Real-Time Clock

SIB Serial Interface Board

SRAM Static Random Access Memory

UART Universal Asynchronous Receiver Transmitter

About This Manual s xiBL1100

Conventions

Table 3 lists and defines the typographical conventions that may be used in

this manual.

Pin Number 1

A black square indicates

pin 1 of all headers.

Measurements

All diagram and graphic measurements are in inches followed by millime-

ters enclosed in parenthesis.

Table 3. Typographical Conventions

Example Description

while

Courier font (bold) indicates a program, a fragment of a

program, or a Dynamic C keyword or phrase.

// IN-01…

Program comments are written in Courier font, plain face.

Italics

Indicates that something should be typed instead of the

italicized words (e.g., in place of filename, type a file’s

name).

Edit

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 | b | c

A vertical bar indicates that a choice should be made from

among the items listed.

J1

Pin 1

BL1100xii s About This Manual

BL1100 Overview



 13

CHAPTER 1: OVERVIEW

BL110014 s Overview

Overview

The BL1100 is a versatile, general-purpose controller. Numerous digital,

analog, and serial channels support complex data collection and control

applications. The BL1100 is programmed using Dynamic C, Z-Worlds

version of the C programming language designed for embedded control.

Figure 1-1 illustrates the BL1100 board layout.

Figure 1-1. BL1100 Board Layout

EPROM

RAM

Expansion

Connector

Crystal

CTC Output

LCD

Interface

Z180

KIO

J12

J10

J6

J31

Power Driver

U1

RS-232

U02

J8 J7J9

J14

J13

J18

J014

RP8

RP9

RS-485 Xmt

U10

U3

ADC

U5

Ref.

U6

J17

Op-Amp

U8

Op-Amp

U7

U011

U9U14

J15

J16

J19

J28

DAC

U12

Buffer

U19

EEPROM

U16

U15

PAL

U11

PAL

U17

RTC

U18

J22

J21

D1

J24

J25

Reset

Button

J1

J2

J3

J4

J5

U4

RN4

RN5

Power Jack

Heat Sink

Analog Input

Analog

Output / Input

RS-485

Power High-Current

Output

J010

Lithium Battery

MAX691

J11

Parallel

Port

Parallel

Port

5 Wago

connectors

Z1

J20

RS-485 Rcv

BL1100 Overview s 15

Features

The BL1100 includes the following features.

 Compactnessdimensions of 5.6" × 4.8" (140mm × 120mm).

 Serial channelstwo RS-232 and two RS-485/RS-422 serial ports.

 Configurable I/O16 programmable TTL and CMOS compatible I/O

lines based on the 16-bit PIO on the Zilog KIO chip.

 High-current digital outputs8 high-current digital outputs based on

the Sprague 5841 driver. Channels can be paralleled for more current.

The drivers are protected against inductive kickback with integral

diodes and are suitable for driving solenoids.

 Analog inputseight-channel A/D converter with configurable inputs.

A built-in temperature sensor uses one of the inputs, leaving seven

analog inputs for use by the application. The A/D converter can have

10-bit resolution (LTC1094) or 12-bit resolution (LTC1294).

 Optional factory-installed analog output12-bit digital to analog

converter (DAC) with output in the range of 0 V to 2.5 V. The Maxim

AD7543 DAC is used with a MAX400 buffer amplifier for a maximum

output of 2 mA.

 LCD interfacestandard LCDs (such as Optrex part number

DMC20481) can be plugged directly into the 14-pin connector. Many

compatible displays are available in various formats (2 ×16 or 4 × 40).

 Z180 microprocessor running at 9.216 MHz with a partial wait state.

Higher clock rates are available for better performance.

 Power failure detection and warning. A nonmaskable interrupt takes

place when power drops below a certain level. The program has a few

milliseconds to shut down.

 Watchdog timer. When enabled, the watchdog timer automatically

resets the board if the watchdog timer system is not regularly hit by

the program. This reliability feature helps a system to recover from

software or hardware failures.

 32K EPROM, supports up to 256K. Accepts either 28- or 32-pin ROM.

 32K battery-backed SRAM, supports up to 512K. Either 28- or 32-pin

RAM can be used. The lithium battery mounted on the board will last

about 10 years.

 512 bytes of EEPROM. One-half of the EEPROM memory (256

bytes) can be write-protected. EEPROM is used to hold the baud rate

and other semipermanent calibration or setup constants. (Can be

expanded to 2048 bytes by using different components.)

BL110016 s Overview

 Battery-backed Epson 72421 real-time clock runs up to 10 years on the

lithium battery.

 Both linear and switching power regulators are present on the board.

 Enclosures are available from different suppliers in table-top plastic

clamshell or wall-mounted industrial versions. For example, the

Hoffman Engineering Company (Anoka, Minn.) enclosure D-864DLB

and mounting plate A-8P6 provide a sturdy steel electrical box. This

box can be wall mounted and connected to electrical conduit.

 The analog inputs, analog output, power, RS-485, and high-current

outputs are on Wago connectors that accept up to approximately #18

copper wire. The Wago connectors have spring loaded clamps that

make it easy to install and remove wires without special tools. The

entire BL1100 series is also available without Wago connectors so that

other connector types may be added instead.

 A 60-pin expansion connector allows a line of expansion boards

designed exclusively for the BL1100 series to be connected to the

microprocessor bus. Selected standard Z-World expansion boards can

also be connected to the PIO header.

BL1100 Overview s 17

(

Table 1-1. BL1100 Series Features

Model Features

BL1100

9.216 MHz clock, 16 configurable I/O, 8 high-current

digital outputs, 8 ten-bit analog inputs, 2 RS-232 and 2

RS-485/RS-422 serial ports, expansion bus, switching

regulator

BL1120 BL1100 with linear regulator

BL1120 BL1100 with 12.288 MHz clock and linear regulator

Table 1-2. BL1100 Options and Upgrades

Option Description

12-bit digital-to-

analog converter

Adds one analog output channel rated 2 mA at 0 V to 2.5 V

10-bit to 12-bit

analog-to-digital

converter upgrade

Upgrades analog-to-digital converter resolution to 12 bits

Op-amp upgrade

Replaces LT1094 op-amps with LT1014 for improved

temperature drift and input offset characteristics

SRAM 128K or 512K SRAM factory installed

BL1120 switching

power regulator

Switching power regulator factory installed on BL1120

Standard Models

The Bl1100 series of controllers has three versions. Table 1-1 lists the

specialized features for these versions. All three versions are available

either with Wago connectors or without any connectors to enable a

customer to use a customer-selected connector.

Options and Upgrades

Table 1-2 lists the options and upgrades available for the BL1100 series.

For ordering information, or for more details about the various

options and prices, call your Z-World Sales Representative at

(530) 757-3737.

BL110018 s Overview

(

Table 1-3. Expansion Boards Used With the BL1100

Expansion Board Description

Standard Z-World Expansion Boards

SE1100 Four SPDT relays

XP8300 Six SPDT relays

XP8400 Eight DIP SPST relays

XP8500

Four 12-bit ADC inputs with signal conditioning and

seven 12-bit ADC inputs without signal conditioning

XP8600 Two DAC outputs

Exp-A/D12 Eight 12-bit ADC inputs

Expansion Boards Unique to BL1100

ADC

One 8-bit PIO, two 4-bit optically isolated PIOs, eight

TTL inputs, one PWM channel, one 20-bit ADC input,

one instrumentation amplifier, and one 4-channel analog

mux

DGL

*

Two 8-bit PIOs, two 4-bit optically isolated PIOs, and

eight TTL buffered inputs

DGL96

**

96 individual I/O points

MUX

One 8-bit PIO, one 6-bit PIO, two 4-bit PIOs, and one

4-channel analog mux

* Available with or without Wago connectors.

** Available in stacking or nonstacking versions. Cannot be

used with BL1120.

Expansion Boards

The BL1100 has a 60-pin expansion connector that allows selected

standard Z-World expansion boards and a line of expansion boards

designed exclusively for the BL1100 series to be connected to the micro-

processor bus. Table 1-3 lists these expansion boards.

Appendix H provides more information about connecting expansion

boards to the microprocessor bus. Appendix K provides detailed

information on the expansion boards unique to the BL1100. Refer to

the manuals on the individual tandard Z-World expansion boards for

more information on the standard expansion boards.

For ordering information, or for more details about the various

options and prices, call your Z-World Sales Representative at

(530) 757-3737.

$

BL1100 Overview s 19

Development and Evaluation Tools

The BL1100 is supported by a Developers Kit that includes everything

you need to start development with the BL1100.

Developers Kit

The Developers Kit includes these items.

 Manual with schematics.

 Programming cables and adapter.

 9 V DC power supply.

 128K SRAM.

Software

The BL1100 is programmed using Z-Worlds Dynamic C, an integrated

development environment that includes an editor, a C compiler, and a

debugger. Library functions provide an easy and robust interface to the

BL1100.

Z-Worlds Dynamic C reference manuals provide complete

software descriptions and programming instructions.

$

BL110020 s Overview

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