From microwave ovens to alarm systems to industrial PLC and DCS control systems, embedded controllers are controlling our world. The microcontrollers that are at the heart of these and many more devices are becoming easier and simpler to use. But when these devices fail the solution to the problem needs to be found and the repairs have to be done quickly. The workshop will help the technician, engineer and even the most casual user understand the inter-workings of microcontrollers along with the most common problems and their solutions. Embedded controllers are used in most electronic equipment today. Embedded controllers are intelligent electronic devices used to control and monitor devices connected to the real world. This can be a Programmable Logic Controller (PLC), Distributed Control System (DCS) or a Smart Sensor. These devices are used in almost every walk of life today. Most automobiles, factories and even kitchen appliances have embedded controllers in them. This workshop covers all aspects of embedded controllers but focussing specifically on troubleshooting and design. The workshop covers design, specification, programming, installation, configuration and of course troubleshooting. This hands-on workshop gives both the novice and experienced user a solid grasp of the basic principles enabling you to go away and apply the material learnt immediately to your application. WHO SHOULD ATTEND? This workshop is designed for personnel with a need to understand the techniques required to use and apply microcontroller technology as productively and economically as possible. This includes engineers and technicians involved with: Consulting Control and instrumentation Control systems Design Electrical installations Instrumentation Maintenance supervisors Process control Process development Project management SCADA and telemetry systems MORE INFORMATION: http://www.idc-online.com/content/practical-embedded-controllers-troubleshooting-and-design-12?id=

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Practical Embedded
Controllers:
Troubleshooting & Design

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Embedded Controllers
• Used in Most Commercial and
Industrial Electronic
Equipment
• Intelligent Electronic Devices
• Used to Control and Monitor
Devices Connected to the Real
World
• The Heart of PLC, DCS and
Fieldbus Control Systems

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Microcontroller Design and Functions
• Central Processor Unit (CPU)
Is the Brain .
• The Program Resides in
RAM, EEPROM or EPROM.
• The Microcontroller Can
Store Data.
• Communicates to the
Outside World.

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Programming
• The Program Is a Sequence
of Instructions That Tell the
CPU What to Do.
• The Instructions Sent to the
CPU Are Very, Very
Simple.
• Upper Level Programming Languages Like
Basic and C++are Often Used.

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Main Components of the
Microcontroller
• CPU
• External Address Bus
• External Data Bus
• External Control Bus
• Internal RAM
• Internal ROM
• Internal EPROM
• Internal EEPROM
• Internal Registers
• Digital Inputs
• Counter Inputs
• Digital Outputs
• Analog Inputs
• Serial Data Communications
• Parallel Ports

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Block Diagram of the HC11

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Microcontrollers
• CPU Uses an Internal Parallel Address and Data
Bus to Communicate With Memory Components
Like RAM, EEPROM and ROM.
• Internal Bus to Talk to Communication Systems,
I / O Ports and Registers.
• RAM, ROM, EPROM and EEPROMs Are Used to
Store (Either Temporary or Permanently) Data and
Program Instructions.

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Microcontroller
• The Parallel Ports Such As A, B, C, D and E Can
Be Used to Transfer Data to and From External
Memory Chips or Devices.
• These Ports Can Be Used to Read and Write to
Devices Like Keyboards and LCDs.
• An External Parallel Data Bus Can Also Be Used
by the Microcontroller to Activate or Read
External Devices Like Switches, Relays, and
LEDs.

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Assembly Language Programming
• In Its Simplest Form, a Program
Is a Sequential Set or List of
Instructions That Tell the
Microcontroller What to Do.
• A Subroutine Is a Small Part of
the Overall Program..

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Start the Car
Put Key in Ignition
Started Turn Key Clockwise to the Start Position
Has the Car Started?
Car Has Started, Release the Key, Go to “End”
If Not, Continue to Hold the Key
Loop to “Started”
End Return to Main Program ( i.e. Drive the Car )
Jump to “Start the Car” Subroutine

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Flow Chart to Start the Car
P u t K e y i n
I g n i t i o n
T u r n C l o c k w i s e
D r i v e t h e C a r
S t a r t t h e C a r
H a s T h e C a r
S t a r t e d ?
N o
Y e s

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Memory Map
• A List of Address Locations in the
Microcontroller System Where the Program,
Ports and Various Other Devices Reside
• Address Locations of RAM, ROM, EPROM
and EEPROM
• Address Locations of “Vectored” Jump
Locations
• Address Location of Input, Output and
Communications Locations

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Vectors
• A Vector Is the Location
of the Beginning of a
Subroutine or Function
of the Program.
• A Vector Could Be a
Memory Location,
Where a Jump Is
Located.

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Inputs and Outputs
• Digital Inputs and Outputs on the
Microcontroller Are Located Within the Ports
A, B, C, D, or E

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Inputs and Outputs
• Some of These Ports Are Defined As Fixed Inputs or Outputs While
Others Are Bi-directional.
• Ports That Can Be Setup Within the Program As Inputs or Outputs
Are Called Bi-directional I/O.
• A Single Bit Changed From a 0 to a 1 in a Particular Register Can
Determine Whether a Line on a Port in an Input or an Output.
• The Definable I/O Is Accessed by Setting up a Register Located at
Certain Addresses in the Memory Map.
• Registers Are Usually 8 Bit Devices Where Each Bit Has a Special
Function.
• Analog Inputs Are Sometimes Included on the Microcontroller, but
Most of the Time They Are a Function of External Chips Connected
to the Microcontroller

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Inputs and Outputs
• The Definable I/O Is Accessed by Setting up a
Register Located at Certain Addresses in the
Memory Map.
• Registers Are Usually 8 Bit Devices Where Each
Bit Has a Special Function.
• Analog Inputs Are Sometimes Included on the
Microcontroller, but Most of the Time They Are a
Function of External Chips Connected to the
Microcontroller

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Data Communication
• RS-232, RS-422 and RS-
485 Are the Most
Common Methods of
Connecting Embedded
Controllers Together.
• RS-232 and RS-422 Are
Point to Point
• RS-485 is Multidrop

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Data Communication
• The Two Fastest Growing
Synchronous Data Communication
Systems in Use Today Are the USB
and Ethernet Systems.
• One Day They May Take Over From
RS-232, RS-422 and RS-485.

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Noise Reduction
• Noise Reduction in Electronic Circuits Is Fast
Becoming a High Priority in Printed Circuit
Board and System Design.
• There Are Two Issues With Respect to Noise
Reduction in Controller Systems.
 One Is Preventing Noise Being Transmitted From the
Device Into the Outside World
 The Other Is Installing Systems That Are Less
Susceptible to Noise From Outside Sources.

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Noise Reduction
• As Electronics on the
Printed Circuit Board
Becomes Faster and
Faster Interference
Increases.

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Noise Reduction
• PLC’s, DCS’s and Other Control Systems Are
Very Susceptible to Noise From External
Sources.
• The Most Common Way Noise Gets Inside a
Controller Is Through the Wiring in the Cable
Run.
• The Wire Connecting the Controller to Sensors,
PLCs and Other Equipment Acts Like an
Antenna.

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Grounding Solutions
• In PCB Design There Are Four Areas of Major
Concern
• Placement of Components
• Track Placement
• Ground Planes
• 1D and 3D Faraday Boxes

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Grounding Solutions
A Faraday Box on a PCB

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Installation Techniques
• Installation of Controllers, Sensors and Wire
Systems Is an Important Part of the Overall
Quality of a System.
• The Best Designed System Will Fail If the
Installation Is Not Done Correctly.
• Proper Installation Is a Very Subjective Thing and
There Are Many Standards.
• Most Installers Rely on Their Experience and
Personal Training.

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Installation Techniques
A Good Installation

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Conclusion
• It Is Impossible to Cover Every Detail Associated With the
Subject of Embedded Control Systems.
• It Is Hoped That This Workshop Will Give the Delegate Some
Hard Hitting Practical Knowledge Concerning the
Troubleshooting and Design of Embedded Controllers.
• Although the Delegate May Never Design the Hardware or
Software Associated With an Embedded Controller, This
Workshop Should Give the Delegate an Overview of the Inter-
workings of the Microcontroller.
• As Time Goes on the Microcontroller Will Become an
Increasingly Important Part of Our Lives. It Is to This End, That
IDC Technologies Hopes the Delegate Will Find This Workshop
of Some Benefit.

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