Thursday, March 11, 2010

Re-Facing the Webcontroller

An interesting thing about the web controller I've posted about earlier is that its interface is a web browser.  Its configuration, current state, and control are executed through Google Chrome, Mozilla Firefox, and yes even MS IE, plus all those others (did you sense a bias?)  The controller is fronted by a web-server.  Furthermore, the designers decided to use cgi calls to change the configuration of the device.  For example, by issuing the string the browser address line: http://192.168.13.15/setoutps.cgi?0000W12=TTL1+ON, the #1 digital output line will be turned on and the browser will be refreshed to show that change.  I remind you, this is from a web browser connected into the same network as the controller.  The two could be inches or miles apart, or through a wireless network.

Consider now leveraging that design with a couple other web technologies that are widely documented and FREE.  Now we have the possibility of getting rid of those ugly yellow screens and replace them with a really flashy custom industrial-looking laptop control panel.  I will post some prototypes later.

Specifically, I will need one more server,  Zend Server Community Edition.  Zend Server gives me the two things I need: a web/application server executing PHP.  The web server needs to send me pages with Javascript in them.  With Javascript, I can do a lot of manipulating of the current page without re-loading the page or requesting a new page.  Javascript also gives me the ability to do requests of other web pages and return that data to the current page.  This technology is called AJAX.  By design and for security reasons a governing committee request that browsers restrict these special page requests to only be from the same web server the Javascript pages are served from.  After a little research, I learned this designed can be programmed around by just a little bit of PHP running the web/app server.  Works for me.

In the end I am going for a single web page that displays the schematic of the brewery, with point and click controls and animated diagrams.

Why all of this work?  Because it is some programming I want to learn, and if I can do it, the result will be pretty cool!!!

More Later...

Tuesday, March 9, 2010

A weekend in the shop

I had a busy weekend in the workshop.


I've been slowly dismantling what was the beginning of a model railroad empire.  Some of the last steps are to remove the masonite backdrops I had installed along the walls and turning the corners into curves.  One of the coolest and most useful piece of layout has been packed away.  For years now I have had a 1' x 8' five track staging yard under the steps to the basement.  It is now packed away in a 1.5' x 2 x 8' crate along with other model railroad stuff.  


Also, I've been building shelving units out of salvaged packing crates.  In general it is pretty nice plywood, but it doesn't come in very big pieces.  I think 2' x 4' is the largest I brought home.  I threw a bunch of it out when put our house up for sale, wishing I had kept some of it.  I built a top shelving unit to add to an existing unit for storage of small stuff all the way to the ceiling.  I also added another shelf to my power tool cart, it's getting heavy and I am considering some larger wheels.


Lastly, I did some work on my electric HLT.  Displayed below is the HLT on top of the brewery tower.  This side view shows the PVC electric box where the 240V connects to the hot water heater element.  I had to modify the tower from the original build.  The mash tun now fits where it should fit, and overall the stand is just tall enough for the mash tun to drain into the kettle on its burner.


From Random Samplings


This side view shows the power distribution panel with a few components missing.  Notice all the high voltage connections are covered by a clear plastic box (removable).  The mash tun is a 5 gallon Igloo water thermos.  The item hanging from the HLT is a fill spigot (upside-down j-shaped).  Still to to be added is a PC power supply, control card, relay board and few sensors.
Here's the front view, now with some working room between the HLT and MT.  Still in the works is to set up the circulation loop to temperature control the mash.  I ran a test on my pump this weekend too.  Although not as powerful as I thought it would be, I think it will work.










Here's a closer up view of the power distribution / control block.  From left to right is the SSR and heatsink, 6-node power distribution block, 2-pole contactor.  The black cable heads to the appliance outlet.  The orange cable is the controlled voltage heading to the heating element.  As noted above, I still need to add the brains and power for the brains.

Thursday, March 4, 2010

Control for Boil Pot

I found this and am considering using it if/when I build an electric kettle.  -TC

Please note the comments below the image:
From Random Samplings


The two components in blue (one capacitor and the potentiometer/rheostat) are where you can make changes to control the frequency of this thing.

The frequency will be:

1.44/(C * R)

So, in this example, the circuit will have a frequency of

1.44/(0.000020 * 100000) = 0.72Hz

It will go through one timing cycle every 1.38 seconds.

By turning the knob on the potentiometer, you can adjust how much time out of that 1.38 seconds the pulse will be ON vs OFF. Turn the knob all the way one direction and the element will basically be on 100% of the time. Turn the knob all the way the other direction and the element will basically be on 0% of the time.

You will need to supply the circuit with a DC voltage source. If you have an old cell phone charger or other old power adapter lying around, you can use that for the DC source.

The end result is that the "dis" (discharge) pin of the 555 timer chip will periodically drain current (as controlled by your knob setting). When the discharge pin is sinking current, you will get a voltage difference between the + and - wires that are marked as "relay control voltage", and the relay will allow your 220V to pass through. When the discharge pin is not sinking current, there will be no voltage drop across the relay control and the relay will not allow the voltage through.

THIS IS NOT NECESSARILY A COMPLETE CIRCUIT. YOU MAY HAVE TO TWEAK THINGS BY ADDING A RESISTOR BETWEEN THE "DIS" PIN AND THE RELAY TO LIMIT THE AMOUNT OF CURRENT THAT WILL BE PULLED THROUGH THE RELAY. THIS IS GOING TO DEPEND ON THE SPECIFIC SSRs YOU BUY.
Also note that many people use two relays to turn on and off both hot wires of the 220V power feed. You will be able to adjust the power with just a single relay on one of the hot lines, but note that this means that the other hot line (the one not passing through the relay) will have a live 110V on it as long as it is plugged in.

Heaven as written by a 17 Year Old Boy




This arrived in my company e-mail from an esteemed colleague, and I wasn't on some mass distribution list, but an intentional selected few.  -TC
P.S. Today faithful steward and member of Peace Lutheran Church, Larry Mulder was laid to rest.

This is excellent and really gets you thinking about what will happen in Heaven. 

17-year-old Brian Moore had only a short time to write something for a class. The subject was what Heaven was like. "I wowed 'em," he later told his father, Bruce. It's a killer. It's the bomb It's the best thing I ever wrote." It also was the last. 
Brian's parents had forgotten about the essay when a cousin found it while cleaning out the teenager's locker at Teays Valley High School in Pickaway County

Brian had been dead only hours, but his parents desperately wanted every piece of his life near them, notes from classmates and teachers, and his homework. Only two months before, he had handwritten the essay about encountering Jesus in a file room full of cards detailing every moment of the teen's life. But it was only after Brian's death that Beth and Bruce Moore realized that their son had described his view of heaven.  
It makes such an impact that people want to share it. "You feel like you are there," Mr. Moore said.. Brian Moore died May 27, 1997, the day after Memorial Day. He was driving home from a friend's house when his car went off Bulen-Pierce Road in Pickaway County and struck a utility pole. He emerged from the wreck unharmed but stepped on a downed power line and was electrocuted.

The Moore 's framed a copy of Brian's essay and hung it among the family portraits in the living room. "I think God used him to make a point. I think we were meant to find it and make something out of it," Mrs. Moore said of the essay. She and her husband want to share their son's vision of life after death. "I'm happy for Brian. I know he's in heaven. I know I'll see him.

Here is Brian's essay entitled:  
                             " The Room.." 
In that place between wakefulness and dreams, I found myself in the room. There were no distinguishing features except for the one wall covered with small index card files. They were like the ones in libraries that list titles by author or subject in alphabetical order. But these files, which stretched from floor to ceiling and seemingly endless in either direction, had very different headings. 
As I drew near the wall of files, the first to catch my attention was one that read "Girls I have liked." I opened it and began flipping through the cards. I quickly shut it, shocked to realize that I recognized the names written on each one. And then without being told, I knew exactly where I was. This lifeless room with its small files was a crude catalog system for my life. Here were written the actions of my every moment, big and small, in a detail my memory couldn't match. A sense of wonder and curiosity, coupled with horror, stirred within me as I began randomly opening files and exploring their content. Some brought joy and sweet memories; others a sense of shame and regret so intense that I would look over my shoulder to see if anyone was watching.

A file named "Friends" was next to one marked "Friends I have betrayed." The titles ranged from the mundane to the outright weird. "Books I Have Read," "Lies I Have Told," "Comfort I have Given," "Jokes I Have Laughed at."

Some were almost hilarious in their exactness: "Things I've yelled at my brothers." Others I couldn't laugh at: "Things I Have Done in My Anger", "Things I Have Muttered Under My Breath at My Parents." I never ceased to be surprised by the contents Often there were many more cards than expected. Sometimes fewer than I hoped. I was overwhelmed by the sheer volume of the life I had lived.

Could it be possible that I had the time in my years to fill each of these thousands or even millions of cards? But each card confirmed this truth. Each was written in my own handwriting. Each signed with my signature.

When I pulled out the file marked "TV Shows I have watched," I realized the files grew to contain their contents. The cards were packed tightly, and yet after two or three yards, I hadn't found the end of the file. I shut it, shamed, not so much by the quality of shows but more by the vast time I knew that file represented.  
When I came to a file marked "Lustful Thoughts," I felt a chill run through my body. I pulled the file out only an inch, not willing to test its size, and drew out a card. I shuddered at its detailed content. I felt sick to think that such a moment had been recorded. An almost animal rage broke on me.

One thought dominated my mind: No one must ever see these cards! No one must ever see this room! I have to destroy them!" In insane frenzy I yanked the file out. Its size didn't matter now. I had to empty it and burn the cards...  
But as I took it at one end and began pounding it on the floor, I could not dislodge a single card. I became desperate and pulled out a card, only to find it as strong as steel when I tried to tear it. Defeated and utterly helpless, I returned the file to its slot. Leaning my forehead against the wall, I let out a long, self-pitying sigh

And then I saw it. The title bore "People I Have Shared the Gospel With." The handle was brighter than those around it, newer, almost unused. I pulled on its handle and a small box not more than three inches long fell into my hands. I could count the cards it contained on one hand.  
And then the tears came. I began to weep. Sobs so deep that they hurt. They started in my stomach and shook through me. I fell on my knees and cried. I cried out of shame, from the overwhelming shame of it all. The rows of file shelves swirled in my tear-filled eyes. No one must ever, ever know of this room.. I must lock it up and hide the key. But then as I pushed away the tears, I saw Him.

No, please not Him. Not here. Oh, anyone but Jesus. I watched helplessly as He began to open the files and read the cards. I couldn't bear to watch His response. And in the moments I could bring myself to look at His face, I saw a sorrow deeper than my own. He seemed to intuitively go to the worst boxes.  
Why did He have to read every one? Finally He turned and looked at me from across the room.. He looked at me with pity in His eyes. But this was a pity that didn't anger me. I dropped my head, covered my face with my hands and began to cry again. He walked over and put His arm around me. He could have said so many things. But He didn't say a word. He just cried with me.

Then He got up and walked back to the wall of files.. Starting at one end of the room, He took out a file and, one by one, began to sign His name over mine on each card. "No!" I shouted rushing to Him. All I could find to say was "No, no," as I pulled the card from Him... His name shouldn't be on these cards. But there it was, written in red so rich, so dark, and so alive.  
The name of Jesus covered mine. It was written with His blood. He gently took the card back He smiled a sad smile and began to sign the cards. I don't think I'll ever understand how He did it so quickly, but the next instant it seemed I heard Him close the last file and walk back to my side. He placed His hand on my shoulder and said, "It is finished."

I stood up, and He led me out of the room. There was no lock on its door. There were still cards to be written.

"For God so loved the world that He gave His only Son, that whoever believes in Him shall not perish but have eternal life." John 3:16

If you feel the same way forward it to as many people as you can so the love of Jesus will touch their lives also. My "People I shared the gospel with" file just got bigger, how about yours?

IF THERE IS ONE EMAIL THAT I HAVE READ THAT NEEDS TO GO AROUND THE WORLD, IT IS THIS ONE, PLEASE PASS THIS TO EVERY ONE YOU KNOW, CHRISTIAN OR NOT! "LET'S FILL OUR OWN FILE CARD" AND MAY GOD BLESS YOU ALL!

You don't have to share this with anybody, no one will know whether you did or not, but you will know and so will He.

Wednesday, March 3, 2010

Warrior's Soul

A writing I found a year ago and adapted to fit where I was at the time.  A story too personal to tell, but maybe it will help someone to see the light at the end of the tunnel.  -TC


Warrior's Soul

I've felt alone most of my life...

So few I've allowed to be close to me, fearing they would betray me or somehow be taken away from me.

Anything precious to me I would keep at bay... never allowing anything that could potentially hurt me to stay with me.

"I Love You"

Those words... when I meant them... could've meant the end of me if none replied in kind... or so I thought.

My children are my world and for them I will travel to the furthest regions of hell... never will they be alone... and God willing... never will they be like their father.

My wife... my love... my soul mate... the one I've hurt and ran from... the one I've neglected and lied to... the one I've hurt because the fear told me she could hurt me... I fell back in love with her the day she said she didn't love me... after months upon months of neglect... and of being alone.

I turn to God when I'm at rock bottom... from depressions it was Him who carried me out... upon reaching the surface again I turned my back on His love and allowed my demons to overtake me in the form of another disease... of anger... and doubt... spritually beat new demons gain hold and grow within me... determined to rock me to my core.

Now I stand... on the verge of defeat once again... and again... with my tail between my legs... I turn to my Lord... the one who would never leave me... no matter how hard I pushed...

Deep inside my heart there has always been love... locked away from the world... "protected" by a fool hearted guard stealing it's sunlight... preventing it from growth...

At first my prayer was in panic... I was losing my wife and I needed Him to stop her... change her heart for me... bring her back to me.

She is still here... but in the physical sense only... so far away...

So I search... I read... and pray... and slip... and pray... and ask... and pray...

... for clarity... strength... salvation... instruction... protection... peace... and love... I pray for love... for the ability to love... to receive love... to learn to love... and to live with love... to feel God's love...

Will my marriage last? God willing...

5 mintues ago I spent a pathetic 10 minutes grilling her with useless question and useless question... will she love me? Will she leave me?
Blah blah blah...

And here I am... praying while I type... with no story to tell... just fingers typing... no structure... but I have prayer... and I have faith...

The patience will come in time... I need it to come in time...

I pray for help... in becoming the man I believe I can be... I pray for knowledge of His will and the strength to carry it out...

This is where I am right now... once again at rock bottom... but looking for the light to guide me out... 

Tuesday, March 2, 2010

Web IO Controller

I found this on ebay. This little gem connects to your home network via ethernet. This device is designed to monitor and control computer servers. So many possibilities!!!

I bought one controller board and three temp sensors.  Temp sensors are located elsewhere on ebay.  In the next few months I will be working this componentry into my brewery design.

The ebay store is IT Cables and the seller is racksys. -TC




Universal Programmable Industrial Controller --WebControl™ with Chassis


+ Introduction


Do you want to monitor temperature of your servers in the co-lo centers and humidity of the server room, turn on and off power from thousands miles away? Do you want to have timer control some of the appliances from remote place? Do you have a need to control machinery for certain sequences of I/O triggers based on digital and analog inputs? WebControl™ is the solution. Simply plug in power and network cable, you can easily configure it through browser interface, yet complex actions can be programmed by this device over a browser. It can be 20 different timer controller; It can also be your temperature monitor and controller, or humidity controller; or programmable logic controller (PLC); or all of the above at the same time.
You can use this device as a burglar alarm to send email to your cell phone, at the same time as remote temperature monitor and air conditioning control, you can also remotely turn on the AC or oven from your office before going home. The limitation is your imagination.
WebControl™ has 8 digital inputs, 3 analog inputs(based on 10bit A/D converter, full scale 0-3V), up to 8 optional DS18B20/DS1822 based temperature sensors, one optional Honeywell HIH-4000 series humidity sensor, 20 custom definable timers to combine and define its 8 digital output in any sequence of those combined input. Its internal clock obtains the precise time from Internet time servers. When each pre-programmed action taking place, it sends an email notice to you. You can also bypass the predefined logic to force any output ON or OFF. Built-in 10 BaseT network interface DHCP client and web server provide easy connection to any existing network.


+ Easy to manage

WebControl™ has built-in DHCP client to obtain IP address from your network′s DHCP server. You can then login to WebControl™ web GUI to control the device, its built-in web server will save your configuration into the configuration file. You can set it to a fixed IP address by disabling DHCP.


From From the Mind of Tim Carlo


For anyone wants to use more than one WebControl™ devices, you can also change its host name to reflect each device′s role in your setup. It will automatically sync its internal clock to the Network Time Services over the Internet. You can setup the proper time zone for it′s to operate in your local time zone.


+ Flexible Output

The eight TTL output is by default at logic zero. When an output is triggered or turned on, it sends out 5V, maximum drive current 20MA. It is capable to drive an optical isolated SSR (Solid State Relay, normal input control voltage 3-32V current is less than 10mA) device to run a motor, siren, light, heater or refrigerator. Optical isolated solid state relay are very easy to find on eBay for very low cost.


From From the Mind of Tim Carlo


You can simply through the web browser to turn on each output, and turn it off any time. If you like to use host computer to control it, you can use wget or Lynx (open source utility) to obtain the sensor value, or control the output from the host command line. You can enter the trigger, be timer, input TTL, analog input, temperature range, or humidity range, to let this controller automatically turn on and off for its 8 output individually.


From From the Mind of Tim Carlo




+ Sophiscated Logic Control Made Easy

The most powerful feature of this device is its programmable output control. You don′t need ladder diagram or programming it through any other software like other industrial PLC. In the GUI, you can define any timer, any temperature sensor, or humidity sensor, any digital iutput(s) or even output(s), any analog input level and their combination to be used as the trigger for any the TTL output. You can AND or OR them to form complex control for each output.


From From the Mind of Tim Carlo




+ Keep you posted

WebControl™ has email notification feature. When a rule set to turn ON or OFF any of the eight outputs, it can send you an email to your desktop, to your cell phone, or to a mailing list. You will know something has triggered the output state change. It can be temperature going above 90 degrees, so that the air condition turned on; or humidity reached 90%, it turns on the dehumidifier; or a security area in your office is being intruded; or any position sensor reached or analog input reached its level.

+ Energy Efficient Device

WebControl™ takes 7-9V DC power source or 12VAC (7VDC is recommended). The first stage regulartor LM2940-5 allows maxium input voltage 26V, however, apply DC voltage beyond 9V may overheat the regulator. If you need to connect 12VDC as power supply for automotive application, you will need to add heatsink to the LM2940. Modify the board will void the warranty. With no load, it only consumes 5MA. If the LED indicator is removed, it only consumes 1MA current. Make it a perfect energy efficient device for anywhere power consummation is watched. When driving power load, the load driven current will be additional to the controller CPU. Everything is included, except the power supply, SSRs, and sensors. Metal Chassis is included for the store purchase. HIH-4000 humidity sensor can be purchased on eBay, optional 16 pin I/O connector type is TYCO ELECTRONICS - 1658622-3 - I/O Connector can be purchased from eBay or NeWark .
User Guide can be viewed online at http://www.cainetworks.com/manuals/webcontrol/WebControlUserGuide.pdf

We do combine shipping to save shipping cost for customers. Due to shipper charges us pickup fee, please check the shipping cost before purchase. Thanks!

Hot Liquor Tank Heating Circuit



Monday, March 1, 2010

Second Post - About a year later

I've been working on building equipment for my homebrewing. As a tech-geek, I have been interested in adding some computer control to my homebrew process.

I have built an electric HLT (Hot Liquor Tank) using a cooler, a 240V hot-water heater element, and some other components.

The idea of using electricity to heat water, or boil wort is appealing ecomically. There are some elements of danger when working with electricity. Electricity needs to be understood, then systems centered around safe use can be designed.

More on this later...