1. Long Range Wireless Mesh Network System Team 4B Kyle Sparger Jason Easterlund Francis Koskei Sponsors: Ryan Ashbaugh Paul Heerwagen from Red River Automation

2. Project Description Wireless mesh network which will interface with a Yaskawa F7 VSD (Variable Speed Drive), which controls a pumping unit. The VSDs will be scattered across large fields with distances up to 20 miles between them. The VSDs will be monitored and controlled from a central station (head-in unit). This station will have a high speed internet connection to allow remote monitoring of the site.

3. Requirements Wireless Unit – Free non-licensed frequency range (900MHz) – Temperature up to 70° C – Range up to 20 miles – $100 per unit – Ideally 120-240VAC 50/60Hz or 24VDC – Use RS485 for serial communication with VSD – Use FHSS for security – Support up to 300 devices – Peer-to-peer networking Software – Intuitive GUI interface – Capable of controlling all VSDs – Capable of monitoring all VSDs – Show alerts if a VSD shuts down (within 10 min) – Programmable data collection rate – Remote Accessibility (over Internet) – Run on Windows machines

4. Flowchart I (uP)

5. Flowchart II (PC)

6. Functional Block Diagram

7. Labor Costs With a Yearly Salary $60,000 And an Overhead Rate of 85% The Effective Cost is $53.37 per hour Estimated Overall Labor Cost: $25,404.12 Actual Overall Labor Cost: $25137.27 The Cost Difference is: -$266.85 The Hour Difference is: 5 hours MemberTotal Working Hours (Projected)Total Working Hours (Actual) Kyle Sparger155 hours235 hours Jason Easterlund178 hours198 hours Francis Koskei143 hours38 hours Team Total Hours476 hours471 hours

8. Parts Cost for Development The total cost of parts for development was $436.69 The breakdown of the cost per part can be seen in the table to the left ItemCost ($)QuantityTotal ($) AC4790 (200mW) Dev Kit+ CL4790 (1W)368.811 M68HC12 Dev Boards020 PC w/serial port020 Miscellaneous (PCB, other electronics)43.601 Power Supply (Test model) (see table below)24.281 VSD plus Power Converter010 Grand Total436.69 Voltage Supply Parts Cost Breakdown (different Quantities) PartPart NumberDist.Distributor Part #125100500 5V reg.KA7805ATUMouser512-KA7805ATU0.550.460.320.224 3.3V reg.KA278R33CTSTUMouser512-KA278R33CTSTU1.791.501.321.08 TransformerVPP16-1250Mouser553-VPP16-125014.1110.729.218.89 RectifierRS402LMouser583-RS402L0.73 0.630.50 100uF CapKME35VB101M8X11LLMouser661-KME35VB101MLL0.200.160.120.11 47uF CapKME25VB47RM5X11LLMouser661- KME25VB47RMLL0.120.100.070.05 22uF CapSME16VB22RM5X11LLMouser661- SME16VB22RMLL0.090.070.060.05 Total ($)17.5913.4711.7310.91

9. Maximum Configuration Parts Cost per Wireless Unit (20 mile range / AC or DC input voltage) PartPart NumberDist.Distributor Part #125100500 TransceiverAC4790-1000MMouser814-AC4790-1000M77.5073.5068.5061.50 68HC12MC9S12C32MFU25Digi-keyMC9S12C32MFU25-ND11.288.537.86 RS-485 Chip MAX488CPA Digi-key MAX488CPA-ND 2.812.121.36 Antenna 0600-00025 Mouser 814-0600-00025 16 PCB Board12 sq. inexpressPCBN/A120.247.485.163.28 Power Circuit See Table 2 N/A 17.5913.4711.7310.91 Total ($)245.42121.10110.61100.91 Parts Cost for Maximum Configuration

10. Minimum Configuration Parts Cost per Wireless Unit (2 mile range / DC input voltage) PartPart NumberDist.Distributor Part #125100500 TransceiverAC4790-200MMouser814-AC4790-200M62.5058.5053.5046.50 68HC12MC9S12C32MFU25Digi-keyMC9S12C32MFU25-ND11.288.537.86 RS-485 Chip MAX488CPA Digi-key MAX488CPA-ND 2.812.121.36 PCB Board12 sq. inexpressPCBN/A120.247.485.163.28 Power Circuit See Table 2 N/Aminus trans. and rectifier2.752.021.891.52 Total ($)199.5878.6569.7760.52 Parts Cost for Minimum Configuration

11. Schedule (Gantt Chart)

12. Results Ability to read and write (local) the VSD registers Communication over wireless link using AC4790 transceivers GUI interface monitors VSD register values over the wireless link Does not send alert if value is out of range – Code in place, but not tested (time issue) No Mesh networking (time issue) – Only point-to-point

13. Recommendations Program uP with C – Easier to debug – Faster to develop – Better portability Add better error handling – Timeout feature for sending/receiving – Send error message if communication with VSD stops Develop a PCB for the project Develop routing protocol for mesh networking capability. Be aware of misleading documentation for AC4790