Danfoss WS 403 Installation guide

MAKING MODERN LIVING POSSIBLE

Installation Guide

WS System Tools

WS 403 Remote Solution

powersolutions.danfoss.com

Installation Guide	WS 403 Remote Solution

Revision history	Table of revisions
	Date	Changed	Rev
	January 2015	Modifications	BC
	November 2014	Four images updated	BB
	November 2014	Published revision	BA
	June 2014	First edition	AA

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Installation Guide	WS 403 Remote Solution
Contents
About this manual
Safety information
	General information........................................................................................................................................................................	6
	Safety advice......................................................................................................................................................................................	6
	General............................................................................................................................................................................................	6
	Health care.....................................................................................................................................................................................	6
	Air traffic.........................................................................................................................................................................................	7
	Explosive environments...........................................................................................................................................................	7
	Antennas........................................................................................................................................................................................	7
	Electronic equipment................................................................................................................................................................	7
	Avoidance of property damage..................................................................................................................................................	8
	FCC notice...........................................................................................................................................................................................	8
	Warranty and liability......................................................................................................................................................................	9
WS information
	Device information........................................................................................................................................................................	10
	WS unit...............................................................................................................................................................................................	10
Requirements for setting up WS 403 unit
	Wiring.................................................................................................................................................................................................	11
	Connectors.......................................................................................................................................................................................	11
	Main connector.........................................................................................................................................................................	11
	5-pin M12 CAN/power connector......................................................................................................................................	12
	GSM/3G connector...................................................................................................................................................................	12
	GPS connector...........................................................................................................................................................................	12
	Connect antennas..........................................................................................................................................................................	12
	Danger due to absorption of RF energy...........................................................................................................................	12
	GSM/3G antenna.......................................................................................................................................................................	13
	GPS antenna...............................................................................................................................................................................	13
	Connect CAN gateway and PC..................................................................................................................................................	13
	CAN bus termination....................................................................................................................................................................	13
	Connect power supply.................................................................................................................................................................	13
	Initial configuration.......................................................................................................................................................................	14
	Indicator elements.........................................................................................................................................................................	14
	CAN LED states..........................................................................................................................................................................	14
	ON LED states.............................................................................................................................................................................	14
	GSM/3G LED states...................................................................................................................................................................	15
	GPS LED states......................................................................................................................................................................	15
WS system tools
WS configurator tool
	Perform node scan.........................................................................................................................................................................	21
	Adapt demo configuration file..................................................................................................................................................	23
	Configure SIM Card.......................................................................................................................................................................	27
	Safety functions settings.............................................................................................................................................................	31
	Remote safety function active.............................................................................................................................................	32
	Remote safety CAN identifier...............................................................................................................................................	32
	Remote safety start Byte position in CAN message.....................................................................................................	33
	Remote safety data type........................................................................................................................................................	33
	Remote safety data byte order............................................................................................................................................	34
	Remote safety trigger condition.........................................................................................................................................	35
	Remote safety compare value U8, U16, U32, S8, S16, S32.........................................................................................	36
	Remote safety time out..........................................................................................................................................................	36
	SIM card details...............................................................................................................................................................................	37
	How to install and setup a SIM card in a WS 403 unit.......................................................................................................	37
	Open the unit.............................................................................................................................................................................	37
	Remove the 4 screws and open the unit..........................................................................................................................	38
WS FW programmer tool
	Open the WS FW file.....................................................................................................................................................................	41

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Installation Guide	WS 403 Remote Solution
Contents
	Connection via CAN.................................................................................................................................................................	44
	Connection via Internet (1 Device).....................................................................................................................................	46
	Connection via Internet (n Device)....................................................................................................................................	49
PLUS+1® Service Tool: connect to a remote device
	Danfoss Telematics login............................................................................................................................................................	57
	Name.............................................................................................................................................................................................	58
	State...............................................................................................................................................................................................	58
	IMEI................................................................................................................................................................................................	58
	Position.........................................................................................................................................................................................	58
	Machine settings............................................................................................................................................................................	59
	Network validation........................................................................................................................................................................	59
	Network status...........................................................................................................................................................................	59
	The status dialog............................................................................................................................................................................	60
	Device information..................................................................................................................................................................	61
	Connection information.........................................................................................................................................................	61
	Connection status...............................................................................................................................................................	61
	Danfoss Telematics and PLUS+1® Service Tool troubleshooting..................................................................................	62
	Logging in...................................................................................................................................................................................	62
	Connecting to device..............................................................................................................................................................	62
Appendix A - Mounting
	Panel-mount installation.............................................................................................................................................................	63
	Orientations of panel-mount installation - option 1....................................................................................................	63
	Parts required for panel-mount installation - option 1...............................................................................................	63
	Orientations of panel-mount installation - option 2....................................................................................................	64
	Parts required for panel-mount installation - option 1...............................................................................................	64
	DIN rail installation........................................................................................................................................................................	64
	Orientation of DIN rail installation......................................................................................................................................	64
	Parts required for DIN rail installation...............................................................................................................................	65

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Installation Guide	WS 403 Remote Solution

About this manual

This document is part of the product and provides important information on the intended use, safety, installation and operation of the device(s) described below. The manual is intended for qualified personnel with advanced knowledge in electrical engineering and CAN bus systems, allowing them to estimate the risks and hazards of operating the device and to integrate it into systems with components of other manufacturers.

Make sure that qualified technicians have sufficient knowledge before designing, modifying or servicing the control system. Read all the important sections of this document before starting any work on the control system.

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Installation Guide	WS 403 Remote Solution

Safety information

In this chapter, you will find important information on how to avoid life-threatening situations and injuries and how to prevent product damage.

General information

These instructions are part of the device.

They contain text and illustrations for the correct handling of the module and must be read before installation or use.

Before deploying the device described in this document, read the entire manual including all safety information.

Adhere to the information contained in this manual and other product documentation. Non-observance of the notes, operation that is not in accordance with use as prescribed below, wrong installation or handling can result in serious harm concerning the safety of people and plant.

Keep this manual for future use and make all information available to anyone deploying the device, even after installation.

Tampering with the device can lead to considerable risks for the safety of people and plant. It is not permitted and leads to an exclusion of any liability and warranty claims.

The device must be installed, connected and put into operation by a qualified personnel. In the event of malfunctions or uncertainties, please contact the manufacturer.

This device is designed to be used in systems which must be checked for conformity with legal requirements prior to placing into operation. The integrator of the system must check and comply with local laws and requirements.

Safety advice

General

Danger due to possibly deficient data transmission WS unit operates using radio signals and cellular networks and is not authorized in applications where a failure of malfunction may result in injury to persons or damage to property.

Deficient network coverage, failure or malfunction of the device may lead to deficient data transmission. Because of this, connection cannot be guaranteed at all times under all conditions.

•Do not operate the device in machines and applications where life depends on the proper operation of this piece of equipment.

•Never rely solely upon any wireless device for essential communications.

Health care

Danger of interference caused by RF energy Medical equipment may be sensitive to RF energy.When in a hospital or other health care facility, observe the restrictions on the use of cellular communication equipment. Switch WS unit off, if instructed to do so by the guidelines posted in sensitive areas.

The operation of cardiac pacemakers, other implanted medical device and hearing aids can be affected by interference from WS unit's antennas placed close to the device.If in doubt about potential danger, contact a physician or the manufacturer of the implanted medical device to verify that it is properly shielded. Pacemaker patients are advised to keep WS unit and its antennas away from the pacemaker while it is on.

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Safety information

Air traffic

Danger of interference caused by RF energy.

The operation of wireless appliances in an aircraft is forbidden to prevent interference with communications systems. Failure to observe these instructions may lead to the suspension or denial of cellular services to the offender, legal action, or both.

•Switch off WS unit before boarding an aircraft.

•Make sure it cannot be switched on inadvertently.

Explosive environments

Danger of explosion.

Operation of any electrical equipment in potentially explosive atmospheres can constitute a safety hazard.

•Adhere to the respective regulations and precautions when you are near petrol stations, fuel depots, chemical plants or where blasting operations are in progress.

•Do not mount the antenna in the close environment of fuel tanks, vessels with explosives and insufficiently shielded electronic devices.

Antennas

Danger due to absorption of RF energy

Mobile communication devices may pose a health risk when operated in the close proximity of persons.

•Install the antenna(s) used for the WS unit devices to provide a separation distance of at least 20 cm / 8 inches from all persons.

•Do not operate them in conjunction or co-locate them with any other antenna or transmitter.

Electronic equipment

Danger of interference caused by RF energy

WS unit receives and transmits radio frequency energy while switched on. Interference may occur if it is used close to TV sets, radios, computers or inadequately shielded equipment.Follow any special regulations and always switch off the WS unit wherever forbidden, or when you suspect that it may cause interference or danger.

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Safety information

Avoidance of property damage

W Warning

Before any installation of the Control system can take place, make sure the ignition lock is turned off and the battery is disconnected. Disconnect the device externally before handling it. Also disconnect any independently supplied output load circuits.

Connecting of Supply Voltage

The supply voltage, should be within the operating range. Connect the supply voltage to power supply. Protect the module by using a fuse. Requisite fuse level should be 1 A, fast (F). To avoid damage to the device, connect/disconnect the main connector only if the power supply to the device is switched off.

NOTICE

Connect the WS to the same power and ground as the Control system. The power supply must be common to both the WS and the Control unit to ensure trouble free communication. Most importantly, the ground connection, must be the same.

NOTICE

Do not use the chassis as the negative terminal.

Polarity reversal

The WS module is protected against power supply polarity reversal, provided an external fuse, max 1 A (Fast) is being used. If this fuse is not used, polarity reversal can damage the unit. Do not connect the housing to Ground externally. This will suspend the reverse voltage protection of the power supply. Applying a reversed voltage in this case will destroy the supply circuits.

IP 65 protection is only ensured if all connectors are plugged in.

•Before exposing the device to dust and water, plug in all connectors.

•Do not immerse the device in water or other liquids.

The maximum torque for fixing the enclosure screws is 1.5 Nm.

•When opening/closing the enclosure, do not exceed this value.

•The device can only be repaired by the manufacturer.

Welding

•Should be done before the installation of the control system. If welding has to be done afterwards, the electrical connections on the system must be disconnected from other equipment, the negative cable must always be disconnected from the battery before disconnecting the positive cable, the ground wire of the welder shall be positioned as close as possible to the place of the welding and the cables on the welding unit shall never be placed near the electrical wires of the control system.

Operation without antennas can destroy the radio modem.

•Do not operate the device without antennas.

•To prevent misuse immediately inform your network operator in case of loss or theft of the SIM card or the radio modem.

FCC notice

The devices covered in the manual may only be used in mobile or stationary systems in which under normal operating conditions the separation distance between the antenna(s) and all persons is at least 20 cm (approx. 8 inches). The antenna(s) must further not be co-located or operated in conjunction with any antenna or transmitter.

According to FCC requirements, the antenna gain, including cable loss, must not exceed the limits of 7.3 dBi in the 850 MHz Cellular band and 12.7 dBi in the PCS 1900 MHz band (WS devices) or 7.2 dBi in the 850 MHz cellular band and 3.5 dBi in the PCS 1900 MHz band respectively (WS devices).

Compliance of WS unit devices in all final product configurations is the responsibility of the integrator.

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Safety information

This equipment has been tested and found to comply with the limits for a Class B digital device, pursuant to part 15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference in a residential installation. This equipment generates, uses and can radiate radio frequency energy and, if not installed and used in accordance with the instructions, may cause harmful interference to radio communications. However, there is no guarantee that interference will not occur in a particular installation. If this equipment does cause harmful interference to radio or television reception, which can be determined by turning the equipment off and on, the user is encouraged to try to correct the interference by one or more of the following measures:

•Reorient or relocate the receiving antenna.

•Increase the separation between the equipment and receiver.

•Connect the equipment into an outlet on a circuit different from that to which the receiver is connected.

•Consult the dealer or an experienced radio/TV technician for help.

Modifications not expressly approved by the manufacturer could void the user's authority to operate the equipment under FCC rules.

Warranty and liability

We assume no liability for defects caused by normal wear, external influences, and errors of installation, operating or maintenance. This also applies if the customer itself or third parties without our approval modify the components of our products (e.g. devices, elements or additional hardware facilities; programs or program elements of the software).

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WS information

This chapter gives an overview of the device elements and functions and also describes the intended use. Refer to the Technical Information document for the lists of available device variants and the product certifications.

See WS 403 Remote Solution Technical Information - L1426375

Device information

The device elements WS 403 is showed in the figure below:

1.'Power/CAN connector'

2.GSM/3G connector

3.GPS connector

4.Mounting holes

5.Aluminum enclosure

6.GPS LED

7.GSM/3G LED

8.ON LED

9.CAN LED

10.Front label

11.Enclosure screws

12.Type label

WS unit

The Danfoss Telematics WS unit is a GSM/GPRS/UMTS modem, with or without GPS and integrated CAN gateway for direct connection to a control system. Machine data is either transferred to the programming or diagnostic system of the machine manufacturer or is buffered on a server.

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Requirements for setting up WS 403 unit

To configure the WS 403 unit, it is necessary to connect to the unit’s CAN network with a computer that has the “WS System Tool” software installed, and has a suitable CAN gateway such as the Danfoss CG150.

Wiring

One of the most important things to consider when installing access control hardware, is the type of cable to be used for connecting together each component of the system.

Incorrect selection or wiring of such cables can cause a wide range of problems, including erratic or nonexistent communication, an increased danger of component damage due to transient voltages, or an increased chance of EMI (Electro Magnetic Interference), all of which can have an adverse effect on the installation. Refer to the Danfoss WS 403 Remote Solution Technical Information for this unit for information on a suitable cable to use.

The following section describes how to connect the device with the components contained in the Starter/Product Kit.

Using incompatible accessories may damage your equipment.If you are using other accessories than those contained in the Starter Kit, make sure that they are compatible with the WS devices.

In order to perform the initial configuration steps, connect the device to your PC as indicated in the image above.

The signals on the CAN connection terminals CAN-Low and CAN-High must match the signals on the CAN terminals of the connected devices. GND of the CAN connector must be connected to CAN-GND.

Connectors

WS403 is equipped with the following connectors:

•1x Main connector

•1x GSM connector

•1x GPS connector

Main connector

The main connector serves for

•connecting the WS device to the CAN bus network

•supplying the WS device with power

Therefore, WS403 has to be connected to the CAN bus network in order to operate.

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Requirements for setting up WS 403 unit

W Warning

•Do not connect the housing to Ground externally. This will suspend the reverse voltage protection of the power supply. Applying a reversed voltage in this case will destroy the supply circuits.

•To avoid damage to the device, connect/disconnect the main connector only if the power supply to the device is switched off.

•To maximize the performance of the GPS receiver, mount the GPS antenna in a place where it is level with the local geographic horizon and has full view of the sky above. If you are using separate GSM/3G and GPS antennas, mounting them at least 2 meters away from each other will also help to improve the GPS performance.

5-pin M12 CAN/power connector

The table and drawing below show the pin assignment of the 5-pin M12 connector. The colors stated in the table below are the conductor colors of the cable listed in the section Accessories and provided in the WS Kit.

CAN/power connector 5-pin M12, male, A-coded, front view

		Pin	Designation	Color	Description
4	3	1	Ground	Brown	Power supply
	5
		2	VCC 6 … 32 V DC	White	Power supply
1	2
		3	n.c. (not connected)	Blue
	P301 764
		4	CAN-High	Black	CAN
		5	CAN-Low	Grey, green	CAN

GSM/3G connector

GSM/3G connector FME, male, front view

Pin	Designation	Description
1	Signal	GSM/3G
1
2	Ground	Shield/housing
2
P301 765

GPS connector

GPS connector SMA, female, front view

	Pin	Designation	Description
	1	Signal	GSM/3G
1	2	Ground	Shield/housing
	2
	P301 766

Connect antennas

Danger due to absorption of RF energy

Mobile communication devices may pose a health risk when operated in the close proximity of persons.

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Requirements for setting up WS 403 unit

•Install the antenna(s) used for the WS devices to provide a separation distance of at least 20 cm [8 inches] from all persons.

•Do not operate them in conjunction or co-locate them with any other antenna or transmitter.

Operation without antennas connected can destroy the radio modem.

•Do not operate WS device without antenna(s).

•To avoid damage to the WS device, connect/disconnect the antenna(s) only if the power supply to the device is switched off.

•Do not mount the antenna(s) inside enclosed metal constructions such as driver cabins because of the Faraday cage effect.

•Do not shorten or lengthen the cable of the antenna(s).

GSM/3G antenna

•Make sure that the device’s power supply is switched off.

•Connect the GSM/3G/GPS combo antenna FMA connector to the device’s GSM/3G connector.

GPS antenna

Use only active GPS antennas with LNA, gain max. 25 dBi, voltage 3 V DC, current max. 30mA.

•Make sure that the device’s power supply is switched off.

•Connect the antenna’s SMA connector to the device’s GPS connector.

To maximize the performance of the GPS receiver, mount the GPS antenna in a place where it is level with the local geographic horizon and has full view of the sky above. If you are using separate GSM/3G and GPS antennas, mounting them at least 2 meters away from each other will also help to improve the GPS performance.

Connect CAN gateway and PC

After connecting the antennas, establish a connection to a laptop via a gateway device by Danfoss

CG150.

Before connecting the Danfoss CG150 to the laptop, you need to install the gateway driver.

CAN bus termination

In each CAN bus system, signal reflections at the end of a wire or cable can cause interference which is one reason for transmission errors. As requires by industry standards, a terminating resistor must be installed at each end of the CAN backbone. This terminator has to match the characteristic impedance of the transmission line.

In CAN bus networks, normally unshielded twisted pair cables are used for signal transmission. These cables have a characteristic impedance of approximately 120 Ohms. Thus a resistor of 120 Ohms has to be placed at each end of the CAN bus line between CAN-High and CAN-Low to reduce the reflections and enable correct communication.

Connect power supply

Before connecting power to the WS device, assure that both antenna wires are connected. For pinout of the power and CAN cable, refer to Connectors on page 11. When powering this device from a power supply rather than a battery, assure that the power supply is capable peak currents of 2 amps and at least 9 volts.

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Installation Guide	WS 403 Remote Solution

Requirements for setting up WS 403 unit

Initial configuration

After connecting all components as described above, you need to perform some initial configuration steps with the help of the WS System Tool.

The initial configuration requires a physical connection to the PC. To configure the SIM card see Configure SIM Card on page 27.

With real-time access, if the SIM card is already configured, you will also be able to configure the device remotely via an Internet connection by using the WS Configurator tool.

Indicator elements

The device is equipped with the following indicator elements:

•1x CAN multicolor LED

•1x ON multicolor LED

•1x GSM/3G multicolor LED

•1x GPS multicolor LED

If green and red colors are simultaneously on, the LED will appear orange.

The following tables describe the LED light characteristics and the corresponding device status.

CAN LED states

LED

Color

Light characteristics

Description

CAN

green

constantly on

CANopen NMT status operational

blinking

CANopen NMT status preoperational

single flash

CANopen NMT status stopped

red

off

No CAN data receiving/ sending

constantly on

CAN error (i.e. bus-off)

flashing irregularly

CAN data receiving/sending

ON LED states

LED	Color	Light characteristics			Description
ON	green	off			No power supply or outside specified
					values constantly
		on			Power supply inside specified values
	red	off			-
		constantly on			Power supply outside specified values

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Requirements for setting up WS 403 unit

GSM/3G LED states

LED

Color

Light characteristics

Description

GSM/ 3G

green

off

-

constantly on

Connected to a server, TCP/IP active

single flash

Connecting to a server If double flash does

not change into continuously on: No data

card OR Antenna faulty

double flash

Initialization status of GSM/3G engine If

double flash does not change into

continuously on: Antenna faulty

triple flash

Reset status of GSM/3G engine

blinking

Idle status of GSM/3G engine, the device is

ready to connect to a server. If blinking

does not change into continuously on:

Device not registered OR Online Mode

Handling not set to “always connect to

server”

red

off

No TCP/IP data over the air receiving/

sending

constantly on

Fatal GSM/3G error (i.e. no SIM card

inserted)

flashing irregularly

TCP/IP data over the air receiving/sending

first green,

green single flash

Code repeated: GPRS provider settings not

then red

correct, e.g. APN

then red constantly on

green double flash

Wrong PIN If this code is repeated: No

SIM / SIM faulty OR GSM module faulty

then red constantly on

GPS LED states

(Models with GPS functionality only)

LED

Color

Light characteristics

Description

GPS

green

Off

GPS is disabled

constantly on

Valid GPS data available

double flash

No valid GPS data available

red

off

GPS antenna OK

constantly on

GPS antenna error (missing or short

circuited)

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Requirements for setting up WS 403 unit

W Warning

If all LEDs are constantly green at the same time and synchronously flashing red (so all LEDs blinking orange), the device is in firmware update mode.

•Do not switch the device off.

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WS system tools

WS System Tools is a group of tools that can be used to configure and upgrade the firewall of the WS 403 device.

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WS configurator tool

The first step is to define the communication between the PC and the CAN adapter and the remote communication unit.

In the WS Configurator main window, select

•Options > Settings > Communication Settings.

The Communication Settings window opens.

This window has two different view modes: Standard or Expert view mode.

For the initial configuration, it is essential to ensure the following settings in the expert view mode.

To switch to expert view mode, select View

•Mode > Expert

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WS configurator tool

1.Select the appropriate CAN bus gateway: Danfoss CG150

2.Select the Unit as Gateway

3.To view a list of available Danfoss Object Hardware ID, click the question mark.

4.From this list, select the corresponding Danfoss CG150 #1 (Channel 0) --Index[0x00].

5.Set the CAN Baud Rate according to your system. The default value is 250 kbit/s.

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WS configurator tool

6.In the Filter tab, select Totally Open CAN Filter and tick For all 11-bit messages and For all 29-bit messages.

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WS configurator tool

7.Select Leave port always open.

8.Select Dual buffered mode connection and set the buffer size to 1000 messages.

9.Select Clear device errors before communication start and Optimize driver speed after open port.

10.Leave all other settings at default.

11.To accept and finish the configuration, click OK

Perform node scan

To check the connection to the remote connectivity device, perform a node scan.

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