HELVAR PSU 12 V 30 W HCG, TOSIBOX Key 200, HCG, PSU 12 V 30 W, TOSIBOX Lock 100 Installation And Setup Manual

Service Kit

Installation and Set-Up Guide

Helvar’s data driven Service Kit enables sending of data from a lighting system to a cloud platform where authorised
users can access it through a REST API or a web browser interface.

The package also provides an encrypted VPN connection for remote Designer assistance to ensure optimal lighting
system performance with very little downtime.

Helvar’s Service Kit consists of the following products:

1. Helvar Cloud Gateway (HCG), a small-form-factor computer that uploads the data from the lighting system to
Helvar’s Cloud Platform via Ethernet or Wi-Fi.

2. TOSIBOX® Lock 100, a small-form-factor computer that provides an encrypted VPN connection to a lighting site’s
router systems for remote Designer assistance.

3. TOSIBOX® Key 200, the cryptoprocessing device that establishes the VPN connection between the PC running
Designer and the TOSIBOX® Lock 100.

Helvar Cloud Gateway TOSIBOX® Lock 100 TOSIBOX® Key 200

Online FAQs: https://helvarsupport.zendesk.com/hc/en-us

ontents

Section Page

1. Overview 2

2. DIN-Rail spacing requirements 2

3. Install the Helvar Cloud Gateway 2

3.1. Mount the PSU on the DIN rail 3

3.2. Mount the Helvar Cloud Gateway on the DIN rail 3

3.3. Connect the PSU, the Ethernet cable for the router network,
and the Ethernet internet cable and/or Wi-Fi antennas 6

4. Configure the router network and the workgroup 7

5. Connect to Helvar Cloud Platform 8

6. Install the TOSIBOX® Lock 100 8

6.1. Mount the PSU on the DIN rail 9

6.2. Mount the TOSIBOX® Lock 100 on the DIN rail 9

6.3. If required, connect the Wi-Fiantennas 9

6.4. Connect the PSU 10

7. Serialise the TOSIBOX® Key 200 10

8. Set up the IP address of the VPN adapter 10

9. Set up the IP address of the TOSIBOX® Lock 100 12

10. Connect the TOSIBOX® Lock 100 to the internet 13

11. Connect the lighting router network to the TOSIBOX® Key 200 15

12. Test the VPN connection 16

13. Technical data 17

13.1. HCG 17

13.2. TOSIBOX® Lock 100 18

13.3. TOSIBOX® Key 200 18

14. System diagram 19

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1. Overview

Follow these steps to install and set up Helvar’s Service Kit package:

1. Install the Helvar Cloud Gateway. For details, see section3 on page2.

2. Configure the router network and the workgroup. For details, see section4 on page7.

3. Connect to Helvar Cloud Platform. For details, see section5 on page8.

4. Install the TOSIBOX® Lock 100. For details, see section6 on page8.

5. Serialise the TOSIBOX® Key 200. For details, see section7 on page10.

6. Set up the IP address of the VPN adapter. For details, see section8 on page10.

7. Set up the IP address of the TOSIBOX® Lock 100. For details, see section9 on page12.

8. Connect the TOSIBOX® Lock 100 to the internet. For details, see section10.

9. Connect the lighting router network to the TOSIBOX® Key 200. For details, see section11 on page15.

10. Test the VPN connection. For details, see section12 on page16.

2. DIN-Rail spacing requirements

KIT Dimensions

Kit Description Starter Next Site Site

Expansion

HCG
TOSIBOX® Lock 100
TOSIBOX® Key 200
PSU 12 V 30 W (HCG)
PSU 24 V 10 W

(TOSIBOX® Lock 100)

✓ ✓ ✓

✓ ✓

✓

✓ ✓ ✓

✓ ✓

(L / W / D) mm Unit size Note

108 / 140 / 28 8 *
99 / 132 / 35 8 *
78 / 21.5 / 9 4 **
90 / 35 / 58 2
91 / 18 / 57 1

Antenna
incl.

W 180 mm
W 165 mm

*

If Wi-Fi is used, place the units in such a way that interference between antennas is minimised. Do not place them in
close proximity.

**

The TOSIBOX® Key 200 is a USB device that requires temporary connection to the TOSIBOX®Lock100
It does not require permanent DIR-Rail space.

during setup only.

3. Install the Helvar Cloud Gateway

Package contents (HCG1TBLK KIT, HCG1TBL KIT and HCG1 KIT)

Helvar Cloud Gateway DIN-rail

mounting plate

HDR-30-12 PSU DC feed plug 12 VDC AC/DC

power adaptor

DIN-rail
mounting clip

Wi-Fi antenna Antenna extension

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Helvar Service Kit: Installation and Set-Up Guide

Screws (2) Washer screws (2)

with magnetic base

Follow these steps to mount the Helvar Cloud Gateway on a standard DIN rail:

1. Mount the PSU on the DIN rail. For details, see section3.1.

2. Mount the Helvar Cloud Gateway on the DIN rail. For details, see section3.2.

3.1. Mount the PSU on the DIN rail

Dimensions (mm) and connections

+V−V

58.4

54.535

90

63.65

45.15

N L

3.2. Mount the Helvar Cloud Gateway on the DIN rail

Mounting dimensions (mm)

Mounting plate Mounting clip

A

90

B

B

A

A

A

B

B

45

35

118

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Restraint

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Mounting procedure

1. Determine the mounting position of the HCG and identify in the following table the mounting plate holes that you
need to use.

Horizontal orientation

To mount the HCG

in this position…

Front panel down

Front panel up

Use these holes

in the mounting plate

B

B

A

A ABBB

A

A

A A B

A

B B

A

Length of mounting

DIN-Rail spacing

clip latch

4U

BB

39 mm56 mm

Vertical orientation

Front panel left

Front panel right

A

A

A

BB

3U

B B

A

A

A

A

B

B

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Helvar Service Kit: Installation and Set-Up Guide

2. Screw the mounting plate to the unit using the appropriate
holes. For details, refer to the preceding table.

3. Do the following to adjust the mounting clip latch to the
length that is appropriate for the required mounting
orientation:

a. Press the upper part of the mounting clip on both

sides.

b. Push the mounting clip latch forwards to unlock it.

c. Slide the latch upwards or downwards to the length

that is appropriate for your mounting orientation. For
details, refer to the table on page4.

d. Push the latch backwards to lock it.

CLICK!

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4. Screw the mounting clip to the mounting plate.

3.3. Connect the PSU, the Ethernet cable for the router network,

and the Ethernet internet cable and/or Wi-Fi antennas

+V −V

PSU

Follow these recommendations to optimise the performance and reliability of the wireless connection:
a. If required, connect the Wi-Fi antenna to the magnetic base of the antenna extension.

b. Set up your Helvar Cloud Gateway as close as possible to the centre of the area for which you want to provide

wireless networking.

c. Keep the antenna away from objects that cause wireless interference. Large metal objects, fluorescent or

halogen lights, microwaves, cordless phones and their base stations and wall ducting or vents can block or
interfere with wireless signals.

d. Place the antenna in an elevated location.

LAN 1
for internet (DHCP)

LAN 2
for router network

Wi-Fi antennas

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Helvar Service Kit: Installation and Set-Up Guide

4. Configure the router network and the workgroup

Before the HCG can communicate with the router system, do the following to configure the router network and indicate
to which workgroup the HCG should connect on LAN 2.

1. Make sure that the HDR-30-12 PSU is on and is connected to the HCG.

2. Turn on the PC that is connected to the HCG.

3. Set the IP address of this PC to the same IP range as the HCG.

Note: The HCG shipping static IP address for LAN 2 is 10.24.15.5, and the subnet mask is 255.0.0.0. Therefore, you could,

for example, set your PC to the IP address 10.24.15.99 and to the subnet mask 255.0.0.0.

4. Open Google Chrome, and navigate to http://10.24.15.5:5000 to access the Network configuration pages of the HCG.

5. In the dialog box, specify how you want to connect to
theinternet:

• To connect to the internet over LAN 1, do one of the
following on the Network tab:

• To obtain the IP address automatically via the Dynamic

Host Configuration Protocol (DHCP), click APPLY
(default option).

• To enter the IP address manually, type the required IP

Address, Broadcast Address and Subnet Mask, and
then click APPLY.

• To connect to the internet over Wi-Fi, click the WIFI tab,
and then do the following:

a. Type the exact SSID and passphrase for the Wi-Fi

network that you want to connect to.

b. Click Apply to save your settings.

6. To change the static IP address for the connection to the
router network, click the LAN2 tab, and then type the new
IP address.

Note 1: The static IP address for the connection to the router

network must be in the same range as the router
workgroup to which the HCG will connect. Changing
this IP address will change the HCG’s address for the
network configuration pages. For example:

• If you change the IP to 10.254.0.100, the
network configuration address will change from
http://10.24.15.5:5000 to http://10.254.0.100:5000.

• If you change the first octet of the HCG to 192.x.x.x,
you will need to set the broadcast address of the
HCG to match accordingly: 192.255.255.255.

Note 2: The static IP address for the connection to the router

network must be a unique IP address that does not
conflict with any other devices on the network.

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7. Click Apply to save your settings.

8. Click Workgroups, type the exact name of the workgroup
that you want the HCG to connect to, and then click Apply.

Note: After the settings that you have entered are saved, a

message will appear at the bottom of the browser. This
is only an indication that your settings have been saved,
not a status that the HCG is connected to the network.

5. Connect to Helvar Cloud Platform

Once you have installed and configured the HCG, follow these steps to make sure that you can access the
Helvar Cloud Platform:

1. Open Google Chrome, and navigate to

https://service.helvar.io

2. Click Sign Up, and then complete the process as directed.

Once you are signed up, Helvar service will grant you
access to your site(s) within two working days.

Note: Before access is granted, an error may be shown on the

web interface.

6. Install the TOSIBOX® Lock 100

This section applies only to HCG1TBLK KIT and HCG1TBL KIT.

Package contents

TOSIBOX® Lock 100 DIN-rail mounting bracket Screws (2)

AMR1-24 PSU DC feed plug 12 VDC AC/DC power adaptor

2 × Wi-Fi antenna Antenna extension with magnetic base

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Helvar Service Kit: Installation and Set-Up Guide

Follow these steps to mount the TOSIBOX® Lock 100 on a standard DIN rail:

1. Mount the PSU on the DIN rail. For details, refer to section6.1.

2. Mount the TOSIBOX® Lock 100 on the DIN rail. For details, refer to section6.2.

6.1. Mount the PSU on the DIN rail

Dimensions (mm) and connections

68

23

12

18

91

51.5

32.3

91

46.9

56.5

6.2. Mount the TOSIBOX® Lock 100 on the DIN rail

For information on how to mount the TOSIBOX® Lock 100 on the DIN rail, refer to Tosibox Inc.’s documentation available
at www.tosibox.com.

6.3. If required, connect the Wi-Fiantennas

Helvar | Data is subject to change without notice.

Wi-Fi antennas

For recommendations on
how to connect the Wi-Fi
antennas, refer to section3.1
on page3.

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6.4. Connect the PSU

+V −V

PSU

7. Serialise the TOSIBOX® Key 200

To serialize the TOSIBOX® Key 200, follow these steps:

1. Insert the TOSIBOX® Key 200 into the USB port of the TOSIBOX® Lock 100, and then wait two minutes.

When the TOSIBOX® Key 200 LED stops blinking or shuts off, the serialisation is complete.

2. Remove the TOSIBOX® Key 200 from the TOSIBOX® Lock 100.

8. Set up the IP address of the VPN adapter

To set up the IP address of the VPN adapter, follow these steps:

1. Connect a PC to the Service port of the TOSIBOX® Lock 100 via an Ethernet cable.

Service to PC

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Helvar Service Kit: Installation and Set-Up Guide

1. Make sure that the Ethernet LAN properties on the PC are
set to obtain an IP address automatically.

2. Open the web browser of the PC, type http://172.17.17.17 (IP address of the Service port) in the address bar, and
then press Enter to access the TOSIBOX® Lock 100 home page.

Disconnected

3. Click Login in the upper right corner to access the TOSIBOX® Lock 100. Login details are printed on the back of the
TOSIBOX® Lock 100.

4. Click SETTINGS > Lock name, type an appropriate name for the TOSIBOX® Lock 100 in the Lock Name textbox, and
then click Save.

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5. Click SETTINGS > Keys and Locks to display the Keys and Locks page.

6. In the Connection name text box, type an appropriate name for this connection.

7. Clear the Deny new IP connections towards this client check-box.

8. From the drop-down list, select the Layer 2 – bridged connection type.

9. In the static IP for the connection, type the IP address that you want the PC to use. This will be the IP address of the
PC’s VPN adapter.

Examples:

• For single-cluster systems: 10.254.1.40 (next key 10.254.1.41, etc.).

• For multi-cluster systems: 10.254.254.40 (next key 10.254.254.41 etc.).

Note: The static IP address for the connection must be a unique IP address that does not conflict with any other devices on

the network.

9. Set up the IP address of the TOSIBOX® Lock 100

To set up the IP address of the TOSIBOX® Lock 100, follow these steps:

1. In the TOSIBOX® Lock 100 home page, click SETTINGS > NETWORK > LAN DHCP server to display the LAN DHCP
server page.

2. Clear the DHCP server for LAN interface check-box, and then click Save.

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Helvar Service Kit: Installation and Set-Up Guide

3. Click NETWORK to display the LAN configuration page.

4. From the Protocol drop-down list, select Static address.

5. In the IPv4 address text box, type the appropriate IPv4 static IP address.

Examples:

• For single-cluster systems: 10.254.1.99.

• For multi-cluster systems: 10.254.254.99.

6. In the IPv4 netmask box, type the appropriate IPv4 netmask.

Example netmask for above IP addresses: 255.0.0.0

Note: The static IP address for the connection must be a unique IP address that does not conflict with any other devices on

the network.

7. Click Save.

10. Connect the TOSIBOX® Lock 100 to the internet

To connect the TOSIBOX® Lock 100 to the internet, do one of the following:

• To use a wired connection, follow these steps:

a. Connect an Ethernet internet cable into the WAN port of the TOSIBOX® Lock 100.

WAN to internet

b. Go to the TOSIBOX® Lock 100 home page and make sure that the internet connection shown under Status is

active.

Note: You should still be connected to the service port, and your browser should still be open to http://172.17.17.17.

But if you are not, repeat steps 1–2 in section 8.

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• To use a wireless connection, follow these steps:

a. Click NETWORK > WLAN to display the Wireless Overview page.

b. Click the Edit button on the right side of the screen to display the Wireless Network page.

c. Under Device Configuration, click the Enable button to active the WLAN.

d. The Enable button toggles to Disable.

e. In the General Setup tab, type the name of the wireless network in the Network Name (ESSID) text box, and then

select Client from the Mode drop-down list.

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Helvar Service Kit: Installation and Set-Up Guide

f. If the wireless network uses encryption and password protection, click the Wireless Security tab, select the type

of encryption from the Encryption drop-down list, and then type the password in the Key text box.

g. Click Save.

11. Connect the lighting router network to the TOSIBOX® Key 200

Connect the lighting router network to the LAN 1 port of the TOSIBOX® Lock 100 using an Ethernet cable.

LAN 1 to router network

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12. Test the VPN connection

To test the VPN connection between the TOSIBOX® Lock 100 and the PC running Designer, do the following:

1. Make sure that the PC running Designer is connected to the Internet.

2. Disconnect the Ethernet cable from the Service port on the TOSIBOX® Lock 100.

Service to PC

3. Insert the TOSIBOX® Key 200 into a USB port on your PC.

An auto play window will appear with options to install the TOSIBOX® Key 200 software.

4. Complete the installation process of the software.

5. When the List of TOSIBOX® Locks window appears, select the appropriate TOSIBOX® Lock 100, and then click
Connect.

6. Wait a few moments for the TOSIBOX® Key 200 to establish connection to the TOSIBOX® Lock 100.

7. Run Designer and check that the remote routers appear in the Devices tree.

8. Connect to the workgroup and use Designer normally.

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Helvar Service Kit: Installation and Set-Up Guide

13. Technical data

13.1. HCG

Power

Input voltage: 12 VDC – 19 VDC

Connectivity

LAN 1: 10/100/1000 Mbps Intel

I210 GbE. For router network.

LAN 2: 10/100/1000 Mbps Intel

I210 GbE.

Wi-Fi: 2 × Wi-Fi antenna

I/O interface

HDMI: 2 × HDMI-out, max. resolution:

3840 × 2160 @ 30Hz, 2560 × 1600
@ 60Hz, 24bpp

On/Off: Power button with LED
USB interface: 4 × USB 3.0

Mechanical data

Dimensions: 140.8 mm × 107.5 mm × 28mm
Mounting: DIN rail (installation in

switchgear/controlgear cabinet)

Weight: 0.56 kg
IP code: IP20

Operating and storage conditions

Ambient temperature:
Relative humidity: Max. 90 %, noncondensing
Storage temperature: –20 °C to +60 °C

0 °C to +40 °C

Conformity and standards

EMC: EN 55032

EN 55024

RED: EN 301489-1

EN 301489-17

Safety: EN 60950-1
Environment: Complies with WEEE and RoHS

directives.

Software compatibility

Designer: 5.4.3 or later

Dimensions (mm)

Connections

Front panel

4 × USB 3.0

2 × HDMI-out LAN 2 for router network

Rear panel

PWR button with LED

Not used

Not used

140.8

Right panel

Not used

Wi-Fi antenna connectors

Left panel

107.5

28

Not used

DC input

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LAN 1 for internet (DHCP)

Not used

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13.2. TOSIBOX® Lock 100

Service

WAN

For technical data, refer to Tosibox Inc.’s documentation
available at www.tosibox.com.

Connections

Dimensions (mm)

132.2

LAN 2

99.2

DC input

VLAN antenna VLAN antenna

13.3. TOSIBOX® Key 200

For technical data, refer to Tosibox Inc.’s documentation
available at www.tosibox.com.

USB 2.0 LAN 1 LAN 3 Not used

Dimensions (mm)

78

66

921.5

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Helvar Service Kit: Installation and Set-Up Guide

14. System diagram

LAN2 port

Ethernet

LAN1, LAN2
or LAN3 port

LAN1 port

Internet

WAN port

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19Doc. 7860396 issue 1,

2018-09-10