Take me home
Projects:
CDi4.P8 Flowmeter, Keller Communicator
LD Series Pressure Transmitters
FlyportPRO
Internet of Things - BME
Internet Enabled, Tomato Garden Watering Thing
ZDL Potential Boards
P5 Evolution Project
P5 Evo
SCi:
CDi3.FTe Submersible, Universal Gas-Field Controller
Keller Digital Pressure Transducers/Transmitters
Burkert Solenoid Modifications
PDL/CDi History: Pembina Lake Erie Datalogger
LD Series Pressure Transmitters
RIP PembinaDataLogger, 1996-2020, P4/P5 Evolution
As mentioned elsewhere in this website, 74 P5-class boards were built in the period beginning in 2004 and ending in 2009, all 74 having the distinction of using a new "re-workable" potting compound. Excluding diving, at least $1 million was spent on equipment and related development during this period, in other words, prior to the CDi3/P7 introduction in 2010. This level of expenditure required a second look at the P3/P4/P5 hardware which had remained essentially unchanged since 1997 with the introduction of the PDL3 board. First encouraging results were obtained in 2016 with the ZDL development and the subsequent installation in June 2017 of the first digital P5-based switcher. For the next three or so years the "second look" was placed on the back burner as it was deemed more important to finish the brand-new 2016 CDi3.LE digital boardset development, an upgrade to the original 2010 P7MAIN digital boardset. The severe side effects of the DELP legal mumbo-jumbo further delayed development, but the P5 "second look" did take place and by the spring of 2020 had evolved into a "second look on everything". Here are some of the results:
  1. The addition of a crystal and two capacitors create the new DUMBO hardware class. In the original 1997-2006 P3/P4/P5 board the UART clock was derived from the CPU clock_out signal, in effect limiting the BRG, Baud Rate Generator in the UART which in turn limited the family to a maximum baud rate of 38,400 baud, see Libby CDi99 (it was the first P5). The additional crystal and two capacitors give the UART its own oscillator and this results in a P5-class board being capable of a maximum baud rate of 115,200 baud. Intensive testing proved that although the board is capable of operating at 115,200 baud it cannot sustain that speed in certain instances resulting in reliability issues. Subsequently the maximum baud rate for the DUMBO class was throttled back to the much more reliable rate of 57,600 baud.
  2. The removal of the original RS232 transceiver and the addition of a small board with an RS485 transceiver create a new DUMBO-class board named LUCY. Both the DUMBO and LUCY boards, in addition to the traditional interval-based switching, also implement switching function #5, the sixth function since the first is function #0, which is a new very low and very high duty cycle-capable switching method. The sixth function does any duty cycle in exactly three (3) 3-second power cycles, if the total on-off period is 48 hours or less. Consider the power consumption implications of this: 1 minute on, 2879 minutes off, total period is 2880 minutes, controller executes the cycle in three 3-second "power ons", total controller "on" time is nine seconds in 48 hours! That's 2.5 or so minutes per month, secondary switching at its best!
  3. The addition of yet another small board with an RS485 transceiver chip and a couple of silicon switch chips creates the CDi1s class of board, the Camaro, something that is 100% functionally and operationally compatible with the CDi3s and CDi3t machine classes, respectively the CorvetteI and CorvetteII.
PDL3/4/5 Derivative Device
Comms:Baud Rate
Battery
Recommended Cable
DUMBO
RS232:57600
Lead-Acid
RS232, 5m or 1.8m
LUCY
RS485:57600
Lead-Acid (Land Use) or NiMH (Submersible Use)
RS485, 5m or 1.8m
CDi1s (Camaro)

Machine Class: DUMBO, Model: LUCY, NiMH, RS485 57600 Baud, Submersible use possible
Function #5 DUMBO:LUCY Switcher
  • All three P5 derivatives DUMBO/LUCY/CDi1s can be assembled with lead-acid batteries for land applications. The lesser DUMBO/LUCY models are only meant to be used with a single analogue transmitter for optional line pressure measurement, so in addition to battery voltage and board temperature, these units also record line pressure if the transmitter is present, zero otherwise.
  • LUCY/CDi1s have new RS485 communications with baud rate increased to 57,600 and optional NiMH batteries so submersible use possible if assembly method *6Z is used.
  • When used with the latest software, DUMBO/LUCY units can perform sixth-function-switching in addition to traditional interval-based switching. WATER or GAS functionality built-in, also known as Fail-Open or Fail-Closed functionality.
Machine Class: CDi1s, Nickname: Camaro
Function #0 CDi1s.FTe, Camaro in a typical 2-TR submersible flow meter application. Capability: Upstream, downstream flow recording only, no switching.
Function #1 CDi1s.FTe, Camaro in a typical 3-TR submersible flow meter application. Capability: Upstream, downstream and casing flow recording only, no switching.
Function #2 CDi1s.FTe, Camaro in a typical 1-TR digital submersible plunger lift application. Capability: Timed switching only,
Function #4 CDi1s.FTe, Camaro in a 3-TR digital submersible plunger lift application. Capability: Upstream, downstream flow recording, timed and smart switching.
Function #0 CDi1s.FTe, Camaro in a 2-TR digital submersible flow meter application. [+] Capability: Upstream, downstream flow recording only, no switching.
Firmware: 1sMF6790:84C6, 32389, SRC
Function #1 CDi1s.FTe, Camaro in a 3-TR digital submersible flow meter application. [+] Capability: Upstream, downstream and casing flow recording only, no switching.
Firmware: 1sMF6791:63C7, 32325, SRC
Function #2 CDi1s.FTe, Camaro in a 1-TR digital submersible switcher application. [+]
Capability: Timed switching only, cannot record flow.
Firmware: 1sMF6792:4B74, 32673, SRC
Function #4 CDi1s.FTe, Camaro in a 3-TR digital submersible switcher application. [+]
Capability: Upstream, downstream flow recording, timed and smart switching.
Firmware: 1sMF6794:D94A, 32597, SRC
Availability
Assembly
Nickname
Boardset
Future Start Max
Board On Time
Batt. Chem./Capacity
RTC
Battery Life
74
CDi1s.FTe.*6Z
Camaro
1998-2006 PDL4/5
1.5 Days
2.2 Seconds
DS1386/Z
14.6 Years
Rebuilt electronics from old 1998-2006 PDL4/5 boards. Pressure measurement: strictly Keller-digital, PA10 digital transmitters never need calibration. Battery chemistry: strictly NiMH, low self-discharge. Cylinders: strictly machine threaded 316 SS. Communications: strictly RS485, units communicate with computer on primary channel, "talk" to their Kellers on secondary channel. Primary channel: 57,600 baud, secondary: 9,600 baud. Power cycle: 2.2 seconds, pressure transmitters powered up for 0.7 seconds. They all record their own battery voltage and after more than 10 consecutive bad battery readings disable switching and stop recording. They all support Hardware Authorization and Debug Output. One box, five functions, two flow meters and three switchers, arranged and numbered in increasing complexity from 0 to 4, see firmware numbers.
Function #3 CDi1s.FTe, Camaro in a 2-TR digital submersible plunger lift application. Capability: Upstream, downstream flow recording and some smart switching.
Function #3 CDi1s.FTe, Camaro in a 2-TR digital submersible switcher application. [+]
Capability: Upstream, downstream flow recording and some smart switching.
Firmware: 1sMF6793:2ABA, 32661, SRC
TR = TRansmitter = PA10 series RS485 digital pressure transmitter, supplied by Keller in Switzerland. These are state-of-art devices, silicone oil and laser-welded diaphragm isolated, with Hastelloy C276 stainless wetted parts. The company allows its clients to buy just the essentials and thus subsequently design and build their own housings, only one type of pressure transmitter to stock!
Other Goodies
The "second look on everything" also created some new functionality which is now shared by all five devices and explained below:
  1. DUMBO/LUCY/Camaro/CorvetteI/CorvetteII Hardware Authorization. It is implemented as a down counter (fuel gauge) of integral seconds decremented appropriately every time a reading is recorded, and replenished to the maximum value of approx. 15,811,200 (15.8 million seconds, 183 days x 86,400 seconds/day, 183 days is six months) every time the controllers are talked to by authorized software. If Software Authorization ever expires, the solenoid is opened, and both switching and recording are disabled if the controller is a switcher and only recording is disabled if the controller is not, in both cases interval is reset to the maximum of 1440 minutes. Hardware Authorization or Re-authorization can subsequently only be performed by qualified individuals.
  2. DUMBO/LUCY/Camaro/CorvetteI/CorvetteII Debug Output. It is a way to know what a controller is doing without actually communicating with it. All five send a line of text out the serial port representing controller state just before shutdown occurs. The next few lines of text is example Debug Output from a CDi1s/Camaro switcher captured with free Tera Term software:

    2020-08-28 01:15:28, SW: 3 B:7.27 T:79.0 1: 0.0 5:-0.092 6:-0.057 SE:15810600
    2020-08-28 01:16:24, SW: 2 B:7.35 T:78.9 1: 0.0 5:-0.073 6:-0.042 SE:15810540
    2020-08-28 01:17:28, SW: 3 B:7.30 T:78.9 1: 0.0 5:-0.069 6:-0.040 SE:15810480
    2020-08-28 01:18:24, SW: 2 B:7.37 T:78.9 1: 0.0 5:-0.068 6:-0.038 SE:15810420
    2020-08-28 01:19:28, SW: 3 B:7.32 T:78.9 1: 0.0 5:-0.086 6:-0.052 SE:15810360
    2020-08-28 01:20:24, SW: 2 B:7.38 T:78.9 1: 0.0 5:-0.088 6:-0.061 SE:15810300
    2020-08-28 01:21:28, SW: 3 B:7.33 T:78.9 1: 0.0 5:-0.068 6:-0.061 SE:15810240

    We have Date, Time, SW=Switch State, B=Battery Volts, T=Temperature, 1=Casing Value, 5=U/S Value, 6=D/S Value, SE=Seconds Remaining. Switch State has 4 possible values, 0=Switching is Disabled and Switch is Off, 1=Switching is Disabled and Switch is On, 2=Switching is Enabled and Switch is Off, 3=Switching is Enabled and Switch is On.
  3. DUMBO/LUCY/Camaro/CorvetteI/CorvetteII Low Battery Detection. They all record their own battery voltage so it wasn't all that difficult to implement this function across all of them. It takes 10 consecutive bad battery readings (battery voltage is below 5.8 Volts) for the controller to recognize a low battery condition. Once the low battery condition is detected the controller wll behave just like it does when Hardware Authorization has expired.
  4. DUMBO/LUCY/Camaro/CorvetteI/CorvetteII Binary Program Matrix:

    64XX CDi1-CDi3 RMe Models, SCi Command Set, Not Implemented, CDiComm Software Bundle
    65XX CDi1-CDi3 RMe Models, Custom Command Set, Not Implemented, CDiDemo/CDiLComm/CDiMComm Software Bundle
    66XX CDi1-CDi3 Fte Models, SCi Command Set, CDiComm Software Bundle

    67XX CDi1-CDi3 FTe Models, Custom Command Set, M=MN=MNR, CDiMComm Software Bundle intended for divers
    00-29, CorvetteI Fte Binaries, CDi3s (2010 P7MAIN) Machine Class, DS1386 RTC, MNR Command Set
    3sMF6700 = CDi3s, DS1386, MN, FTe, 3TR Digital Switcher (6700)
    3sMF6701 = CDi3s, DS1386, MN, FTe, 1TR Digital Switcher (6701)
    3sMF6702 = CDi3s, DS1386, MN, FTe, 2TR Digital FlowMeter(6702)
    3sMF6703 = CDi3s, DS1386, MN, FTe, 3TR Digital FlowMeter(6703)
    3sMF6704 = CDi3s, DS1386, MN, FTe, 3TR Digital FlowMeter(6704)
    30-59, CorvetteII Fte Binaries, CDi3t (2016 CDi3.P7) Machine Class, DS1386 RTC, MNR Command Set
    3tMF6730 = CDi3t, DS1386, MN, FTe, 2TR Digital FlowMeter(6730)
    3tMF6731 = CDi3t, DS1386, MN, FTe, 3TR Digital FlowMeter(6731)
    3tMF6732 = CDi3t, DS1386, MN, FTe, 1TR Digital Switcher (6732)
    3tMF6733 = CDi3t, DS1386, MN, FTe, 2TR Digital Switcher (6733)
    3tMF6734 = CDi3t, DS1386, MN, FTe, 3TR Digital Switcher (6734)
    60-89, Ferrari FTe Binaries, CDi3f (2016 CDi3.LE) Machine, DS1553 RTC, MNR Command Set,
    3fMF6760 = CDi3f, DS1553, MN, FTe, 2TR Digital FlowMeter(6760)
    3fMF6761 = CDi3f, DS1553, MN, FTe, 3TR Digital FlowMeter(6761)
    3fMF6762 = CDi3f, DS1553, MN, FTe, 1TR Digital Switcher (6762)
    3fMF6763 = CDi3f, DS1553, MN, FTe, 2TR Digital Switcher (6763)
    3fMF6764 = CDi3f, DS1553, MN, FTe, 3TR Digital Switcher (6764)
    90-97, Camaro FTe Binaries, CDi1s (1997-2006 P3/P4/P5) Machine Class, DS1386 RTC, MNR Command Set
    1sMF6790 = CDi1s, DS1386, MN, FTe, 2TR Digital FlowMeter(6790)
    1sMF6791 = CDi1s, DS1386, MN, FTe, 3TR Digital FlowMeter(6791)
    1sMF6792 = CDi1s, DS1386, MN, FTe, 1TR Digital Switcher (6792)
    1sMF6793 = CDi1s, DS1386, MN, FTe, 2TR Digital Switcher (6793)
    1sMF6794 = CDi1s, DS1386, MN, FTe, 3TR Digital Switcher (6794)

Conclusions

  • CDi1s is 100% functionally and operationally compatible with the latest CDi3s and CDi3t controllers. Only LUCY and CDi1s have optional NiMH batteries so they would be candidates for submersible use if *6Z assembly is used. Lead-acid batteries are still acceptable for DUMBO/LUCY/CDi1s land use, but unacceptable for submersibles.
  • All lake devices to be compatible with CDiMComm, M=MNR, software. Since LUCY/CDi1s have been turned up a bit, and since CDi3s/CDi3t have been turned down a bit, there is only one baud rate for all: 57,600.
  • All digital submersible transmitters communicate at 9,600 baud so they are interchangeable, for example, the casing transmitter from unit A will work as the casing transmitter in unit B without any other changes.
  • Only one type of transmitter to buy for all possible jobs!
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