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DL4500
User Manual
47 pgs2.66 Mb0

Equustek DL4500 User Manual

DL4500
User Manual
Revision 2.02 – January 26, 2007
Contents
1 General Operation and Applications ..................................................4
2 Hardware Specifications and Layout..................................................5
2.3 Hardware Layout .............................................................................................6
3 Mode of Operation ................................................................................7
3.2.1 BIOS Manager Options......................................................................7
4 Switch and LED Indicator Functions .................................................9
4.2.1 Power-Up and Reset Sequence ..........................................................9
4.2.2 Normal On-line Operation...............................................................10
4.2.3 On-Line, Power-Up and Reset Errors .............................................11
4.2.4 Off-Line Modes ................................................................................12
5 Configuration ......................................................................................13
5.1.1 IP Address........................................................................................13
5.1.2 Telnet................................................................................................16
DF1 MultiMaster .............................................................................17
Standard Tunnel...............................................................................18
Modbus TCP ....................................................................................19
5.2.1 Configuration...................................................................................20
DF1 MultiMaster .............................................................................21
Standard Tunnel...............................................................................22
5.2.2 Port Settings.....................................................................................23
5.3.1 Configuring Modbus Parameters ....................................................24
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5.3.1 Configuring Modbus Parameters using the DL Offline Manager...26
5.4.1 DH+ Node Address..........................................................................28
5.4.2 DH+ Baud Rate ...............................................................................28
5.4.3 DH-485 Node Address .....................................................................29
5.4.4 DH-485 Baud Rate...........................................................................29
6 Firmware Upgrade..............................................................................30
6.2 DL32 Configuration Software .......................................................................33
7 Wiring Diagrams.................................................................................36
7.4 DH-485 Cable ................................................................................................37
8 DL4500 Typical Applications.............................................................38
8.3 DL4500-MEDH+...........................................................................................39
9 Frequently Encountered Problems ...................................................40
9.2 Cannot communicate to DH+ node 0 using the DL4500-MEDH+ ...............41
Appendix A: TCP/IP Tutorial..............................................................42
A.4 Valid IP Addresses.........................................................................................44
Appendix B: RSLinx Setup ..................................................................46
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1 General Operation and Applications
The DL4500 hardware platform was designed to be a gateway which interfaces your Ethernet TCP/IP or Modbus TCP Networks to AB’s Data Highway Plus (DH+), Remote I/O, or DH-485 networks. Thus extending the life of existing Allen-Bradley PLC’s and SLC’s without Ethernet Interfaces. It comes in a DC powered Din-Rail Mountable compact cabinet for ease of portability and installation. The DL4500 combines the Lantronix Ethernet Microprocessor with our proven A-B interface.
The DL4500 comes with a RJ-45 Connector for the 10 Base-T Ethernet link, and a 3 pin Phoenix plug for connection to A-B networks. Power is supplied via a 2 pin Phoenix type plug which allows for 9-27 Volts DC to be connected. Included is a RS232 DB9 Configuration Port for access to the BIOS and Flash Burn Utilities.
Configuration of the operating parameters is done quickly and easily via the Ethernet Link by Telnet or the supplied Lantronix Device Installer software. Serial port encapsulation of the DF1 protocol over TCP/IP is handled by the supplied COM Port Redirector software also supplied by Lantronix. Current releases of the software can be obtained from Lantronix’s Website.
Modbus TCP communication is handled by any generic Modbus TCP driver, tested ones include Citect, Parijat, and Kepware. There is also the option of RAW tunneling of DF1 using other Ethernet TCP/IP drivers such as Kepware.
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2 Hardware Specifications and Layout
The DL4500 Hardware Platform has the following specifications.
2.1 Operating Specifications
Our DH+/RIO versions A-B Channel allows Synchronous Transformer Coupled SDLC connection to Allen Bradley DH+ or RI/O. Speeds of 57.6K, 115.2K and 230.4K Baud are available in both networks.
Our DH-485 versions A-B Channel allows for Isolated DH-485 (RS485) connection to Allen Bradley DH-485 network. Speeds of 4800, 9600 and 19.2K (default) Baud are available.
Ethernet Channel allows 10 Base-T connections to TCP/IP and other Ethernet networks.
Currently Full and Half Duplex DF1 protocol with BCC error checking is tunneled over the Ethernet TCP/IP link. Modbus TCP makes use of our proven Modbus to AB network interoperability.
Simple Parameter Configuration using menu driven Windows based Programs via Ethernet 10 Base-T.
Configuration and Reset Pushbuttons go into BIOS features and Flash Setup and do a full Hardware Reset.
Operating Parameters are stored in Non-Volatile Serial EEPROM.
The DL4500 uses FLASH upgradeable firmware from either the supplied DL32 configuration program or once can use a HyperTerminal type program set to 9600,N,8,1 and XON/XOFF flow control.
Bi-Color (Green/Red) LED’s for Ethernet and A-B Channels indicates activity and status. Green POWER LED indicates power on. Green LED’s for Ethernet Link and Tunneling Status. Red LED for Ethernet Diagnostic Status.
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2.2 Physical Specifications
Dimensions: 1.2" H x 4.75" D x 3.2" W (30.4 x 120.7 x 81.3 mm) - Weight 0.56 Lbs (0.2 Kg) Installation: Metal Enclosure; Desktop, # 8 Bolts, or Din Rail Mounting Operating Environment: 32 to 122 °F (0 to 50 °C) Storage: -40 to 185°F (-40 to 85°C) Humidity: 5% to 95% non-condensing Power: 9-27V DC - 1.8 Watts
2.3 Hardware Layout
This Section contains information of the physical position and purpose of the components of the DL4500.
The top row contains the following connectors. Going left to right.
• 2 pin Power Connector
• A-B Network 3 pin Screw terminal (Phoenix Type)
The LED’s on the left side going from top to bottom.
• Ethernet Activity (TX/RX)
• A-B Network Status
• DL4500 Operating Mode and Status.
The LED’s on the right side going from top to bottom.
• Ethernet Activity (Port TX/RX)
• Lantronix COBOX Diagnostic LED.
• 10 Base-T Ethernet Link Status
The RESET pushbutton is on the left side, the Configure pushbutton is on the right side.
The bottom side of the DL4500 has the following connectors: Going Left to Right.
• 9 Pin DM9M connector for Configuring the BIOS and Firmware
• RJ-45 connector for 10 Base-T Ethernet communications
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3 Mode of Operation
3.1 Online Mode of Operation
Online Mode is the normal operating Mode of the DL4500. In this mode the Channels are now configured as they are defined by the A-B Network and Configuration. The DL4500 is ready to interface your equipment. The Reset pushbutton automatically puts the DL4500 into Online mode.
3.2 Offline Mode
Once the Configure Pushbutton is Pressed the Offline BIOS Manager is started. Using either the DL32 configuration software and the “DL Offline Manager” option or a Windows Hyper Terminal type program with com port settings of 9600 Baud, 8,N,1 and Xon/Xoff flow control.
BIOS MANAGER for DL4500-ENET- Revision 1.01 Oct 15,03 (c) Equus Technologies. 2003
MAIN MENU
1 - Restore EEPROM to Factory settings 2 - WRITE new Firmware
3 - Memory DUMP 4 - OFF-LINE Diagnostics 5 - DEBUG Mode
6 - FIRMWARE Version 7 - ONLINE
MAKE SELECTION (1-7) -
3.2.1 BIOS Manager Options
Restore EEPROM to factory settings
Once pressed you will be asked “Restore EEPROM to defaults (Y/N)?” If the answer is “Y”es then the Online parameters will be reset to defaults of Address 1, and settings of 9600,N,8,1 on the communication Channel to the COBOX.
Write New Firmware
Once pressed the message “This *WILL* overwrite DATALINK system code enter (Y/N) to proceed” will be displayed. Hit “Y” and the next message will appear telling you that it is alright to send the new firmware to the Flash; ERASING FLASH, PLEASE WAIT...
SEND FIRMWARE TEXT FILE NOW...
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Once the message to send the firmware appears then either click on the “Burn Flash System File” button to select the .txt file to send, or send the Text File under HyperTerminal. Wait for an “*A-OK* BURN COMPLETE!” message to appear.
Memory Dump
This is used to display the RAM memory of the DL4500. This should only be done after contacting Equustek Solutions to debug problems.
Off-Line Diagnostics
Starts a series of tests to test the DL4500’s hardware and should only be done if instructed so by a trained person.
Debug Mode
Starts up a DL4500 internal Debug mode that can be used by trained personnel to debug problems and check hardware configuration and operation.
Firmware Version
Once selected the current DL4500 model and version numbers will be displayed. Can be used to check the correct firmware was burnt into the Flash or if the DL4500 has the most up to date firmware in the Flash.
Online
Does a soft “software” reset of the unit to put it online. This will NOT reset the COBOX (Ethernet) hardware.
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4 Switch and LED Indicator Functions
4.1 Switch Functions
Reset Pushbutton
The Reset pushbutton will perform a complete hardware reset of the DL4500. It is identical to a complete power cycle and will cause the DL4500 to go through its LED start-up sequence as defined in Section 5.2.1. A complete hardware reset is needed on changing any online operating parameters.
Configure Pushbutton
The Configure pushbutton takes the DL4500 out of On-Line operation mode and puts it in the BIOS Manager mode. When this mode has been entered the Ethernet and Status will be RED and A-B Network will be out. To put the unit back On-line it is necessary to either press the Reset or cycle the DC power supplied to the DL4500.
4.2 Indicator Functions
4.2.1 Power-Up and Reset Sequence
On Power-up or after the Reset button has been pressed the DL4500 executes a self diagnostic check-up or the ram and flash firmware. The correct LED indicator sequence to show the DL4500 is functioning properly is as follows: After all LEDS go out.
LED Status
Power Green Continuously Status Green for 0.5 seconds A-B Network Green for 0.5 seconds Ethernet Green for 3 seconds
After this sequence the DL4500 goes into the On-line mode of Operation. The LED indicators will behave in the certain way defined by the DL4500 model used. Most likely the A-B Network will be solid or flashing depending on the A-B Network used.
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4.2.2 Normal On-line Operation
The following is a description of the normal operation of the LED’s on the DL4500.
LEFT LED’s Description of Operation
Power Green Indicates Power is being supplied to the DL4500.
Ethernet Flashes GREEN for 0.5 seconds when a character is Received or
Transmitted. If Characters are being received of transmitted faster than this then it might appear the LED is on SOLID. Flashes RED for 0.5 seconds if a NAK is received or transmitted. Will also flash if all serial communication buffers are full.
A-B Network (DH+ )
On Hardware Reset will flash GREEN and RED until a valid DH+ network is detected. This is the AUTO BAUD Rate detection mode, the DL4500 will automatically connect at the DH+ speeds of 57.6K, 115.2K and 230.4K Baud. LED will switch to on solid once the DL4500 is on the DH+ network as a valid node address. LED will flash GREEN when the DH+ is set to a certain Baud rate but is not on network.
(DH-485)
On Hardware reset the A-B Network will flash GREEN at a 1 second rate when the DH-485 is not on network. Once a valid network is running the LED will flash GREEN much more rapidly (approx. every 0.1 seconds), the rate depends on how busy the network is.
Status Used for Determining Operating Mode and DL4500 Status
RIGHT LED’s Description of Operation
TX/RX Lights Solid green to indicate an Ethernet socket is idle. Blinks
green to indicate an Ethernet socket has been established and active.
Diagnostic Blinks or lights solid red in combination with TX/RX led to
indicate diagnostics and error detection.
Link Lights Solid Green to indicate Ethernet Port is connected to the
10Base-T network.
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4.2.3 On-Line, Power-Up and Reset Errors
The following table describes the meaning of LED patterns if the internal diagnostic tests detect an error on Reset/Power-Up.
LED Pattern Description of Problem
Ethernet, A-B Network, and Status Flashing RED
Ethernet, A-B Network, and Status Solid RED
Start-up Sequence keeps repeating
A-B Network Flashing RED
The flash has not be burnt properly and the A-OK was not transmitted. Please reburn the flash with the correct text file. Contact Customer Support for help.
The BIOS has been corrupted. A new Flash Chip has to be supplied by the factory. Please contact Customer support.
The DL4500 EEPROM is corrupt.. Please Restore to Factory Settings (See Section 4.3) and then reconfigure the unit.
There is a duplicate node on the A-B network. The DL4500 has been assigned a node address that is already in use.
Right TX/RX and Diagnostic
Red solid, green (TX/RX) blinking:
1x:EEPROM checksum error 2x:RAM error 3x:Network controller error 4x:EEPROM checksum error 5x:Duplicate IP address on the Ethernet Network 6x:Software does not match hardware
Red blinking. Green (TX/RX) blinking:
4x: Faulty Ethernet connection 5x:No DHCP response received
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4.2.4 Off-Line Modes
The following table describes the meaning of LED patterns in the different Off-Line modes of operation.
LED Pattern Description of Operation
Ethernet & Status Solid RED
Ethernet & Status Solid Green A-B Network Solid Red
Ethernet Solid Red A-B Network & Status Solid Green
BIOS Manager
Offline Hardware Diagnostics Testing Mode
Offline Debug Mode
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5 Configuration
The following sections describe how to setup and configure your DL4500 for the desired online operating parameters. To configure your DL4500, the following software will be needed.
Configuration Software
• Device Installer - Used to assign IP address and update Lantronix
• ComPort Redirector - Creates a virtual COM port and redirects it to the PC’s
• DL32 Configuration - Used to map Modicon registers/coils to Allan-Bradley
After the IP address of the DL4500 is assigned, you must then telnet to the DL4500 to setup the internal communications between the Lantronix daughter board and the DL4500 motherboard. These settings are reset every time an IP address is assigned.
daughter board firmware.
Ethernet port.
data files with the DL4500-MEDH+ or MEDH-485.
5.1 Device Installer
The Device Installer is used to configure the IP address of the DL4500 as well as configure the internal communication settings between the Lantronix daughter board and the DL4500 mother board. The most recent version of Device Installer is Device Installer 3.6.
5.1.1 IP Address
To assign an IP address to the DL4500, open the Device Installer Software. You will then see a screen as shown below.
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The following steps are used to assign an IP address to the DL4500.
1. Click on the Search button to have the Device Installer find the DL4500. If the
Device Installer finds the DL4500, the device should appear. If the device cannot be found then follow the instructions at the end of the IP Address section.
2. Highlight the device and click on the Assign IP button. Choose the “Assign a specific
IP address” option and click Next. The following window will appear.
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3. Enter the desired IP address, subnet mask, and default gateway (if required) and click
Next.
4. To assign the chosen IP address to the DL4500, click the Assign button. When the IP
address is assigned, a message stating that the IP address was successfully assigned should appear. Click the Finish button to close the screen and go back to the main menu.
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