Another Rebooting Problem

[MobileMe]

I sent both boards in to get fixed. I have another board that i setup for my dad so he could monitor his sump pumps. His board was locking up. I replaced it with a new board and it's seems to be working great.

I'm trying to figure out why it locks up. I put a temperature, humidity and light sensor on it. Programmed it to turn on lights and set outputs per temp and humidity. The board was working fine for two days until last night when it locked up. The temperature sensor was reading 0.0 fail and the Plc was not working. I couldn't send any commands to the board at all. The Plc restarted on its own after accessing it through a browser. I had to reset the temperature sensor and it started reading fine again.

What could be causing this?

 

[pittom]

A couple questions
 
1-what are you using to turn on lights relay? what kind?(how is it hooked up)
 
2-did anything get hot on board
 
3-what power supply   volts? and amps?

 

[MobileMe]

I'm using a wireless remote outlet wired to a relay board.  One relay to turn it on and another to turn them off.  The relay board has it's own power and same for the wireless remote.  I have a photoresistor on one of the outlets light indicator which is hooked up to a digital input.  It lets me know when the outlet is on or off. 
 
The board is running at the same temp as the other board which is in the same location.
 
I'm using a 9 volt 1 amp power supply.

 

[CAI_Support]

I sent both boards in to get fixed. I have another board that i setup for my dad so he could monitor his sump pumps. His board was locking up. I replaced it with a new board and it's seems to be working great.

I'm trying to figure out why it locks up. I put a temperature, humidity and light sensor on it. Programmed it to turn on lights and set outputs per temp and humidity. The board was working fine for two days until last night when it locked up. The temperature sensor was reading 0.0 fail and the Plc was not working. I couldn't send any commands to the board at all. The Plc restarted on its own after accessing it through a browser. I had to reset the temperature sensor and it started reading fine again.

What could be causing this?

Which version firmware on your Dad's board?  I think it will help if you mention which version firmware. 

 

[MobileMe]

v03.02.11

 

[CAI_Support]

3.02.11 firmware was released in 2011.  Do you want to update its firmware?  I think you should at least upgrade it to 3.2.13 firmwrae version.

 

[MobileMe]

I'm confused.  Is it a firmware issue?  Of course I would like to update the firmware, but wouldn't you want to take it to the latest version?  There is also the matter of having to send the board in and pay for the firmware update which gets less appealing the more I think about it.

 

[CAI_Support]

Sure, if you sending the board for update, we will update to the latest firmware always.
When firmware is couple years old, it is better to update fhe firmware first, that way we can eliminate the possibility caused by older firmware.  Newer firmware added a lot of funcitons and features, also changed code layout in the storage eeprom.  I think those changes resulting newer firmware running a lot better.

 

[MobileMe]

The board was running fine over the weekend until today.  Could it be my plc code?
 
START
    DELAY 5000    
    SET VAR1 17
    SET VAR3 22
    SET VAR5 1  
    SET VAR6 695
    SET RAM6 695
    SET VAR7 36
    EMAIL EM2
LOOP:
    TSTEQ VAR5 1
    CALLSUB HEAT
    TSTEQ VAR5 0
    CALLSUB OFF
    TSTLT T1 650
    CALLSUB TEMPALERT
    CALLSUB RESETS
    TSTEQ CH VAR1
    CALLSUB LITEONM
    TSTEQ CH VAR3
    CALLSUB LITEOFFM
    GOTO LOOP   
    END
HEAT:
    CALLSUB TEMPSET
    CALLSUB HUMSET
    TSTEQ VAR8 0
    CALLSUB TEMPNORM
    TSTEQ VAR8 1
    CALLSUB AUTO
    TSTLE T1 RAM5
    CALLSUB HEATON
    TSTGE T1 RAM4
    CALLSUB HEATOFF
    TSTLT H1 RAM8
    CALLSUB HUMON
    TSTGT H1 RAM7
    CALLSUB HUMOFF
    RET
TEMPSET:
    SUB RAM4 VAR6 RAM3
    TSTNE 6 RAM3  
    GOTO SETOFF   
    SUB VAR6 RAM5 RAM3
    TSTNE 6 RAM3  
    GOTO SETON   
    RET    
SETOFF:
    ADD VAR6 6 RAM4
    RET    
SETON:
    SUB VAR6 6 RAM5
    RET
HUMSET:
    SUB RAM7 VAR7 RAM3
    TSTNE 2 RAM3
    GOTO SETHOFF
    SUB VAR7 RAM8 RAM3
    TSTNE 2 RAM3
    GOTO SETHON
    RET
SETHOFF:
    ADD VAR7 2 RAM7
    RET
SETHON:
    SUB VAR7 2 RAM8
    RET
TEMPNORM:
    ANDB RAM1 32 RAM2
    TSTEQ 0 RAM2
    SET VAR6 RAM6
    ANDB RAM1 8
    BNZ SET8ZERO
    ANDB RAM1 16
    BNZ SET16ZERO
    ORB RAM1 32 RAM1
    RET
AUTO:
    TSTEQ CH 23
    CALLSUB TEMPDOWN
    TSTEQ CH 6
    CALLSUB TEMPUP
    TSTEQ CH 8
    CALLSUB TEMPDOWN
    TSTEQ CH 17
    CALLSUB TEMPUP
    GOTO RESET32
    RET
RESET32:
    ANDB RAM1 32
    BNZ SET32ZERO
    RET
SET32ZERO:
    XORB RAM1 32 RAM1
    RET
TEMPDOWN:
    ANDB RAM1 8 RAM2
    TSTEQ 0 RAM2
    SET RAM6 VAR6
    TSTEQ 0 RAM2
    SUB VAR6 20 VAR6
    ORB RAM1 8 RAM1
    GOTO RESET16
    RET
TEMPUP:
    ANDB RAM1 16 RAM2
    TSTEQ 0 RAM2
    SET VAR6 RAM6
    ORB RAM1 16 RAM1
    GOTO RESET8
    RET
RESET8:
    ANDB RAM1 8
    BNZ SET8ZERO
    RET
SET8ZERO:
    XORB RAM1 8 RAM1
    RET
RESET16:
    ANDB RAM1 16
    BNZ SET16ZERO
    RET
SET16ZERO:
    XORB RAM1 16 RAM1
    RET  
HEATON:
    SET OP1 1
    SET OP3 0
    RET
HEATOFF:
    SET OP1 0
    TSTEQ OP3 0
    SET OP2 0
    RET
OFF:
    SET OP1 0
    SET OP2 0
    SET OP3 0
    RET
HUMON:
    TSTEQ OP1 1
    SET OP2 1
    RET  
HUMOFF:
    SET OP2 0
    SET OP3 0
    RET

TEMPALERT:
    ANDB RAM1 4 RAM2
    TSTEQ 0 RAM2
    EMAIL EM1
    ORB RAM1 4 RAM1
    RET

RESETS:
    TSTEQ IP8 0
    CALLSUB RESET1
    TSTEQ IP8 1
    CALLSUB RESET2
    TSTGT T1 660
    CALLSUB RESET4
    RET    
RESET1:
    ANDB RAM1 1
    BNZ SETONZERO
    RET
SETONZERO:
    XORB RAM1 1 RAM1
    RET
RESET2:
    ANDB RAM1 2
    BNZ SETOFZERO
    RET
SETOFZERO:
    XORB RAM1 2 RAM1
    RET
RESET4:
    ANDB RAM1 4
    BNZ SET4ZERO
    RET
SET4ZERO:
    XORB RAM1 4 RAM1
    RET

LITEONM:
    TSTEQ CM VAR2
    GOTO LITEONS
    RET
LITEONS:
    TSTEQ CS 0
    GOTO LITEON
    TSTEQ CS 1
    GOTO LITEON
    TSTEQ CS 2
    GOTO LITEON
    TSTEQ CS 3
    GOTO LITEON
    TSTEQ CS 4
    GOTO LITEON
    TSTEQ CS 5
    GOTO LITEON
    RET
LITEON:
    ANDB RAM1 1 RAM2
    TSTEQ 0 RAM2
    GOTO LON
    RET
LON:
    SET OP7 1  
    DELAY 500   
    SET OP7 0  
    ORB RAM1 1 RAM1
    RET
LITEOFFM:
    TSTEQ CM VAR4
    GOTO LITEOFFS
    RET
LITEOFFS:
    TSTEQ CS 0
    GOTO LITEOFF
    TSTEQ CS 1
    GOTO LITEOFF
    TSTEQ CS 2
    GOTO LITEOFF
    TSTEQ CS 3
    GOTO LITEOFF
    TSTEQ CS 4
    GOTO LITEOFF
    TSTEQ CS 5
    GOTO LITEOFF
    RET
LITEOFF:
    ANDB RAM1 2 RAM2
    TSTEQ 0 RAM2
    GOTO LOFF
    RET
LOFF:
    SET OP8 1
    DELAY 500
    SET OP8 0
    ORB RAM1 2 RAM1
    RET

 

[CAI_Support]

That is a long PLC program, I can see you really have some serious logic there.
You mentioned before the board is running 3.02.11 firmware. If that is the case, that version does not support ORB or any bitwise operation.

 

[MobileMe]

I had access to another board running 3.02.16c. 
 
I put a lot of time working on this project.  I've changed out everything I could think of.  Went as far as rerunning cable to the board.  I wanted to use a webcontrol board to run my furnace, so I needed the board to be stable.  I've invested in three boards and only one seems to be stable.  My dad always told me "you get what you pay for", so I think its time to quit while I'm ahead.  At this point I think it is time to move to another platform.  I certainly feel I gave it a fair shake. 
 
Thanks to everyone that has helped me.  I've learned a lot.

 

[CAI_Support]

Sorry you feel that way.  We have testing boards running in our lab for years and do not experience stability problem. If we saw any problem, we would fix it already. I am sure you did run into problems and we are working with you to isolate them.  A lot of times, the external noise on the wires is not we can easily duplicate and not really sure if that is your case. 
 
There are a lot of people running WebControl with good result.  When running a complex setup like this, it does have chance not getting the result you expected at once. That is not necessary the problem of WebControl. We always want to work with customers by find out what was wrong and help them to make it work, Many times, the external sensor could cause problem, because they are directly connected together. if we can make any improvement, we always do.
 
Just last week, one custoemr told us his setup was not stable.  Then later, he found out once he removed one of his temperature sensors, everything runs smoothly. So he replaced that sensor. It turned out his temp sensor short out 5V supply from time to time.   We are happy he found out the problem was sensor. We don't feel bad if customers not happy with us for any problem. Because if we buy anything ourselves, we expect it to work, too.  We are always here to help.

 

[MobileMe]

I'm sure a lot of people have had good experiences with the webcontrol board, but after reading CAI_SUPPORTS's last post, I am convinced the webcontrol board is not the product I want to continue to use. No product is infallible. I'm sure it gets extensive testing, but it is a mass produced product which is prone to flaws. Case in point, sending out boards with faulty firmware and a resister that needed to be replaced.

CAI is not a consumer based company. They are an enterprise oriented business. Charging for firmware updates and Plc code is not consumer friendly no matter how you put it.

I have been using these boards for over a year now and I most certainly gave it the benefit of the doubt. At some point I just have to say enough. I liked them so much, I recommend them to my employer which in turn have been testing a few of them. The tests have been positive, but I can't get behind them anymore.

 

[CAI_Support]

Hi MobileMe,
 
I am sorry you felt that way. We just got two boards you sent in which you claimed to have the stability problem on 5V.  We did check on both boards, they both perfectly working. You told us the 5V is up and down, we checked the 5V is stable at 4.98V with our variable output power supply which ranging from 7.5V to 11V. It is possible when you working on the wire without turn off the power, the short caused your power supply failed.
 
We do not supply power supply for the board, or sensors. When any of those gone bad, WebControl will not work properly.  We understand your frustration. To be fair, some of those frustrations were bad power supply or sensor.  We appologize to anyone ran into software bug, or analog noise in the past.  Although almost all software has bug, especially the recent firmware bug was caused by software tool bug we purchased from our vendor, we still think our software bug is not excusable. We tried our best to support you and any customer who use our products, do not matter how much WebControl cost and we spent hours or even days to help them getting thing to work.
 
We have discussed firmware update before. This board has limited code space. If we implemented the remote update, it will force us to remove some features. There is no perfect solution.  WebControl is currently sold for the hardware cost.  Firmware and support are all not really charged to customers.  When we charge for firmware update, that is merely for handling charge.  How much anybody else charge for half a hour work these days?  In addition, when anyone purchased a new board and needing any additional function or feature, we always work with you try to add those support for you without any charge. 
 
We are an engineering firm, we make our products for engineers and people who has interested in engineering.  We hope our products will help those who interested in engineering to learn more electronics, to help people automate things around them.  We appreciate your past working with us.  We appreciate your feedback, does not matter good word or not that good.  Maybe you could think again, WebControl firmware now has no known bug, its analog noise problem fixed already.