ICC MBP-100, NETWORK GATEWAY MBP-100 Instruction Manual

NETWORK GATEWAY SERIES

ICC

INDUSTRIAL CONTROL COMMUNICATIONS, INC.

MBP-100

MODBUS PLUS

MULTIPROTOCOL NETWORK GATEWAY

August 2008 ICC #10498-3.100-001

Introduction

Thank you for purchasing the ICC MBP-100 Modbus Plus Multiprotocol Network Gateway. The MBP-100 allows information to be transferred seamlessly among many different fieldbus networks with minimal configuration requirements. The MBP-100 provides one Modbus Plus port, one RS485 port, one RS232 port, and three common serial ports for direct connectivity to Toshiba 7-series, 9-series, 11-series or VF-nC1 Adjustable Speed Drives (ASDs). These various communication ports operate independently, and are configurable along with the unit’s internal point database via a serial console interface.

The gateway currently provides support for the following protocols:

 Modbus RTU (RS485 master & slave)  Modbus RTU (RS232 master & slave)  Toshiba ASD (common serial master)  Toshiba ASD (RS485 master)  Mitsubishi 500-series & 700-series ASD (RS485 master)  Modbus Plus (host)

New network drivers are continuously being added, and can be downloaded for free from our web site.

Before using the MBP-100 network gateway, please familiarize yourself with the product and be sure to thoroughly read the instructions and precautions contained in this manual. In addition, please make sure that this instruction manual is delivered to the end user of the MBP-100, and keep this instruction manual in a safe place for future reference or unit inspection.

This instruction manual describes the device specifications, wiring methods, maintenance procedures, supported functions, usage methods and firmware update procedure for the MBP-100 network gateway.

For the latest information, support, firmware releases or product configuration files, please vi sit http: //www.iccde sig ns.com

Before continuing, please take a moment to ensure that you have received all materials shipped with your kit. These items are:

• MBP-100 gateway

• 2 meter DB9-RJ45 RS232 port cable (part number 10425)

• Documentation CD-ROM

MODBUS PLUS IS A REGISTERED TRADEMARK OF SCHNEIDER ELECTRIC

MBP-100 Modbus Plus Multiprotocol Network Gateway

User's Manual

Part Number 10498-3.100-001

Printed in U.S.A.

Industrial Control Communications, Inc. reserves the right to make changes

and improvements to its products without providing notice.

Notice to Users

INDUSTRIAL CONTROL COMMUNICATIONS, INC.’S PRODUCTS ARE NOT AUTHORIZED FOR USE AS CRITICAL COMPONENTS IN LIFE-SUPPORT DEVICES OR SYSTEMS. Life-support devices or systems are devices or systems intended to sustain life, and whose failure to perform, when properly used in accordance with instructions for use provided in the labeling and user's manual, can be reasonably expected to result in significant injury.

No complex software or hardware system is perfect. Bugs may always be present in a system of any size. In order to prevent danger to life or property, it is the responsibility of the system designer to incorporate redundant protective mechanisms appropriate to the risk involved.

Usage Precautions

• Please use the gateway only when the ambient temperature of the environment into which the unit is installed is within the following specified temperature limits:

Operation

: -10 ∼ +50°C (+14 ∼ +122°F)

Storage

: -40 ∼ +85°C (-40 ∼ +185°F)

• Avoid installation locations that may be subjected to large shocks or vibrations.

• Avoid installation locations that may be subjected to rapid changes in temperature or humidity.

Operating Environment

• Proper ground connections are vital for both safety and signal reliability reasons. Ensure that all electrical equipment is properly grounded.

• Route all communication cables separate from high-voltage or noise- emitting cabling (such as ASD input/output power wiring).

Installation and Wiring

• Do not touch charged parts of the drive such as the terminal block while the drive’s CHARGE lamp is lit. A charge will still be present in the drive’s internal electrolytic capacitors, and therefore touching these areas may result in an electrical shock. Always turn all drive input power supplies OFF, and wait at least 5 minutes after the CHARGE lamp has gone out before connecting communication cables.

• To avoid misoperation, do not connect any gateway terminals to either the ASD’s E/GND terminals, the motor, or to any other power ground.

• When making common serial connections between the gateway and Toshiba ASDs, do not use cables that exceed 5 meters in length.

• For further drive-specific precaution, safety and installation information, please refer to the appropriate documentation supplied with your drive.

• Internal ASD EEPROMs have a limited life span of write cycles. Observe all precautions contained in this manual and your ASD manual regarding which drive registers safely may and may not be repetitively written to.

• When used without an Auxiliary power source (Toshiba ASD common serial mode), the gateway derives its control power from the connected drives. Therefore, removing power to all connected drives will also cause the gateway to lose power.

ASD Connections

TABLE OF CONTENTS

1. The Network Gateway Series Concept.......................................6

2. Mechanical Diagrams...................................................................7

2.1 Enclosure..............................................................................................7

2.2 Mounting Clip........................................................................................8

2.3 External Interface..................................................................................9

3. Feature Summary........................................................................11

4. Installing the Gateway................................................................14

4.1 RS-485 Network in Use.......................................................................14

4.2 Toshiba ASD (Common Serial) Network in Use..................................15

4.2.1 Installation for G7 ASDs..................................................................15

4.2.2 Installation for S7, S9, S11, A7 and VF-nC1 ASDs.........................17

5. RS485 Port Electrical Interfaces ...............................................19

6. Environmental Specifications ...................................................20

7. Maintenance and Inspection .....................................................21

8. Storage and Warranty ................................................................22

8.1 Storage................................................................................................22

8.2 Warranty.............................................................................................. 22

9. LED Indicators ............................................................................23

9.1 Toshiba ASD Common Serial Port Indicators .....................................23

9.2 RS232 (MMI) Port Indicators...............................................................23

10. Configuration Switches .........................................................24

11. Auxiliary Power Supply..........................................................25

12. Unit Configuration Concepts.................................................26

12.1 Port and Protocol Configuration..........................................................26

12.2 Timeout Configuration.........................................................................26

12.3 Point Configuration..............................................................................27

12.4 General Configuration Procedure........................................................28

13. Console Access......................................................................30

13.1 RS232.................................................................................................30

13.1.1 Requirements.............................................................................30

13.1.2 Connection .................................................................................30

13.1.3 Application Configuration........................................................... 30

13.2 Invocation........................................................................................... 33

13.3 Main Menu.......................................................................................... 34

13.3.1 View/Edit Points.........................................................................35

13.3.2 View/Edit Ports .......................................................................... 44

13.3.3 Load Points................................................................................46

13.3.4 Xmodem Point File..................................................................... 46

13.3.5 MBP-100 Information................................................................. 48

14. Protocol-Specific Information ...............................................49

14.1 Modbus............................................................................................... 49

14.1.1 Coil & Discrete Input Mappings.................................................. 50

14.1.2 Modbus RTU Slave.................................................................... 51

14.1.3 Modbus RTU Master.................................................................. 51

14.2 Modbus Plus....................................................................................... 53

14.3 Toshiba Common Serial ASD Protocol............................................... 54

14.4 Toshiba RS485 ASD Protocol ............................................................ 54

14.5 Mitsubishi ASD Protocol..................................................................... 57

14.6 Teco-Westinghouse ASDs.................................................................. 61

14.6.1 MA7200 .....................................................................................61

14.6.2 PA7300...................................................................................... 62

15. Modicon PLC Programming Examples.................................64

15.1 Ladder Logic and MSTR Instructions.................................................. 64

15.1.1 MSTR Parameters..................................................................... 65

15.1.2 MSTR Inputs and Outputs .........................................................66

15.2 MSTR Function Error Codes .............................................................. 66

15.3 MSTR Read Example.........................................................................66

15.4 MSTR Write Example......................................................................... 67

15.5 MSTR Global Read Example.............................................................. 68

15.6 MSTR Global Write Example.............................................................. 69

16. Firmware Updates...................................................................70

16.1 Requirements..................................................................................... 70

16.2 Connection ......................................................................................... 70

16.3 Using the RFU Utility .......................................................................... 71

16.3.1 Required Files............................................................................ 71

16.3.2 First-Time Configuration ............................................................71

16.3.3 Transmitting Firmware Files....................................................... 73

16.4 Wrap-Up............................................................................................. 74

1. The Network Gateway Series Concept

The MBP-100 is a member of the ICC Network Gateway Series product family. Members of this family are designed to provide a uniform interface, configuration and application experience. This commonality reduces the user’s learning curve, reducing commissioning time while simplifying support. The MBP-100 provides simultaneous support for many different communication protocols, allowing complex interchanges of data among otherwise incompatible networks.

The heart of the Network Gateway Series concept is an element called the “point database”. The point database is entirely user-configurable, and provides the mapping information that allows requests from the various supported networks to be interpreted and stored in a common format. This allows data to be routed from any supported network to any other supported network.

Additionally, the point database provides the added benefit of “data mirroring”, whereby current copies of point values (populated by a “source port” designation) are maintained locally within the gateway itself. This greatly reduces the request-to-response latency times on the various networks, as requests (read or write) can be entirely serviced locally, thereby eliminating the time required to execute a secondary transaction on a different network.

When properly configured, the gateway will become essentially “transparent” on the networks, and the various network devices can engage in seamless dialogs with each other.

2. Mechanical Diagrams

2.1 Enclosure

Figure 1: Enclosure Dimensions (units are inches)

2.2 Mounting Clip

Figure 2: Mounting Clip Dimensions (units are inches)

2.3 External Interface

Chassis

GND

Modbus Plus

Network

Figure 3: Bottom View

Reserved

MMI (RS232)

port

Modbus Plus Node

Address Switches

RS485

port

AUX Power

Modbus Plus

Status LED

Figure 4: Front View

ASD Link

LEDs

Data Write

LEDs

ASD #2

ASD #3

ASD #1

Figure 5: Top View

3. Feature Summary

Modbus Plus Port

Standard DB9 connector. Supports both standard (MSTR) read and write as well as global data read and write instructions. Any internal data point has the option of being mapped to the gateway’s “get” or “put” global data. “Get” global data can be configured on a point-by-point basis to originate from any existing device on the network, providing for powerful and efficient peer-to-peer communication.

RS485 Port

One half-duplex 2-wire RS485 port (A / B / Signal Ground / Shield). This port allows a selection of various master and slave protocols to be assigned to it.

RS232 Port

One RS232 port that can be used to configure the unit, update the internal firmware, upload/download configuration files or act as a control protocol port. Use the included DB9-to-RJ45 RS232 cable to interface with this port.

Toshiba ASD Ports

Three common serial (aka logic level) ports for connection of Toshiba 7-series, 9-series, 11-series or VF-nC1 ASDs. ASD connections use the same standard RJ45 style 8-conductor UTP patch cables: any standard CAT5 Ethernet cable (found in most electronics stores) 5 meters or less in length can be used. ASD connections are automatically established and continuously monitored: no drive configuration needs to be performed to connect the unit to the drives. Just plug it in – it’s that simple.

Power Supply

When connected to Toshiba ASDs via the ASD1 / ASD2 / ASD3 ports, can be either powered directly from the attached ASDs, or from the auxiliary power (“POWER”) input jack. All other non-Toshiba applications require the use of the “POWER” input to supply power to the unit. When more than one power source is connected, the unit will draw its control power from the source with the highest supply voltage.

Supported Protocols

 Modbus Plus  Modbus RTU (RS485 master & slave)  Modbus RTU (RS232 master & slave)  Toshiba ASD (common serial master)  Toshiba ASD (RS485 master)  Mitsubishi 500-series & 700-series ASD (RS485 master) (also used by

MGI Technologies, Inc. ASDs)

New network drivers are continuously being added, and can be downloaded for free from our web site.

Text-Based Console Configuration

Unit configuration is performed via a text-based console interface, available locally over the RS232 port via a standard PC terminal program such as Microsoft Windows HyperTerminal®.

Configuration File Upload/Download

A unit’s configuration can be uploaded from / downloaded to a PC, which provides the capability for PC-based file backup and easy configuration copying to multiple units. Pending availability, sample configuration files and related documentation may also be downloaded from our web site, uploaded to a unit, and custom-modified to suit a specific application.

Network Timeout Action

A per-port and per-point 2-level configurable network timeout action can be programmed that allows each internal point to have its own unique “fail-safe” condition in the event of a network interruption.

Indicators

2 green LEDs exist on each of the ASD ports and on the RS232 port connector. Refer to section 9 for more detailed information about the LED indicators and their meanings.

Field-Upgradeable

As new firmware becomes available, the unit can be upgraded in the field by the end-user. Refer to section 16 for more information.

Versatile 3-Way DIN-Rail Mounting System

The unit’s enclosure is provided with a mounting clip attached to the rear of the unit. This clip allows the unit to be mounted 3 different ways:

• For DIN rail mounting, snap the mounting clip onto a standard DIN rail, and then snap the unit enclosure onto the clip’s retaining tabs. This allows easy removal or repositioning of the unit on the DIN rail during wiring.

• For panel mounting, the mounting clip can be bolted directly to a flat panel via the two bolt holes at the top and bottom of the clip. Refer to section 2.2 for mounting clip mechanical details. Once the mounting clip is securely attached to the panel, the unit enclosure can be snapped onto the clip’s retaining tabs.

• For fixed DIN rail mounting, a combination of the above two techniques can be employed. First, snap the mounting clip onto a DIN rail and position it in its desired location. Then, the mounting clip can be bolted to the DIN rail support panel, securing it in place. Lastly, the unit can be snapped onto the fixed mounting clip.

In all cases, the unit can be easily unsnapped from the mounting clip to temporarily provide easier access to the chassis ground terminal or network connector.

4. Installing the Gateway

The gateway’s installation procedure will vary slightly depending on the chosen mounting method and the networks that will be used.

4.1 RS-485 Network in Use

Note that in order to power the unit when not connecting to Toshiba ASDs via the common serial ports, the optional 120VAC/9VDC power supply (ICC part number 10456) or a user-supplied power source meeting the requirements outlined in section 11 must also be installed.

1. Mount the unit via the desired method (refer to page 12 for more information).

2. Connect the Modbus Plus network to the “NETWORK” DB9 connector. Be sure to follow all published guidelines pertaining to Modbus Plus network connections, layout and routing.

3. Connect the RS485 network to the pluggable terminal block. Refer to section 5 for detailed connection information. Ensure that the terminal block is fully seated into the terminal block header, and route the network cable such that it is located well away from any electrical noise sources, such as ASD input power or motor wiring. Also take care to route the cable away from any sharp edges or positions where it may be pinched.

4. Take a moment to verify that the gateway and all network cables have sufficient clearance from electrical noise sources such as drives, motors, or power-carrying electrical wiring.

5. Connect the power supply to the gateway’s “POWER” jack.

4.2 Toshiba ASD (Common Serial) Network in Use

The gateway connects to each drive via the drive’s common serial (logic level) communication port, typically located on either the main drive control board (G7, S11), on the front of the drive enclosure under a small snap-on cover (A7, S9), on the right-hand side of the drive enclosure under a small snap-on cover (S7), or on the bottom side of the drive enclosure (VF-nC1). Although in general no drive parameters need to be configured in order to use the gateway, it is advantageous to check that the drive’s common serial communication data rate is set to its maximum speed. Because the gateway will communicate to each drive only at the drive’s configured data rate, this will provide the fastest response time for drive-to-network data transfers. For information on checking the drive’s common serial communication data rate, refer to the appropriate manual supplied with your drive.

Note that the common serial communication parameters of each drive are handled independently by the gateway, which means that different drive families may be connected to different channels of the unit in any combination, and that the drives connected to each channel may simultaneously communicate to the unit at completely different baud rates, parity settings, etc.

Drives can be connected to the gateway on any ASD channel in any order or combination. When more than one drive is connected to the unit, or if the optional auxiliary power supply is used, the gateway will draw its control power from the source with the highest power supply voltage.

Installation of the gateway should only be performed by a qualified technician familiar with the maintenance and operation of the connected drives. To install the gateway, complete the steps outlined in the following sections related to your specific drive.

4.2.1 Installation for G7 ASDs

1. Mount the unit via the desired method (refer to page 12 for more information).

CAUTION! Verify that all input power sources to the drives to

be connected have been turned OFF and are locked and tagged out.

3. DANGER! Wait at least 5 minutes for the drive’s

electrolytic capacitors to discharge before proceeding to the next step. Do

not touch any internal parts with power applied to the drive, or for at least 5 minutes after power to the d rive has been removed. A hazard exists temporarily for electrical shock even if the source power has been removed. Verify that the CHARGE LED has gone out before

continuing the installation process.

4. Remove the drive’s front cover / open the drive’s cabinet door (refer to the appropriate drive manual for instructions how to do this).

5. The drive’s LCD panel (also called the “Electronic Operator Interface” or “EOI”) can communicate with the drive via either the RS485/RS232 channel (CNU1/CNU1A) or the common serial channel (CNU2/CNU2A). Because the gateway uses the common serial channel, the LCD panel must be configured to use the RS485/RS232 channel. If the drive to be connected is currently using CNU2 (on the drive control board) and CNU2A (on the LCD panel), then this connection must first be switched over to CNU1 (on the drive control board) and CNU1A (on the LCD panel). Refer to Toshiba’s documentation for any precautions or notices regarding this connection change. If the LCD panel is already connected via the RS485/RS232 channel, then no change is required.

6. Configure the drive’s LCD panel to communicate via the RS485/RS232 channel by setting parameter ”Communication Setting

Parameters...Communication Settings...Select LCD Port Connection” to “RS485/232 serial”.

7. Connect the drive’s common serial communication port (CNU2) to one of the ASD channels of the gateway with the communication cable (communication cable is not included with the gateway kit). When choosing cables for this connection, standard 24 AWG category 5 (CAT5) unshielded twisted-pair (UTP) 8-conductor cables found in Ethernet networks in most office environments can be used. The maximum allowable length for these cables is 5 meters. Although there are many varieties and styles of CAT5 UTP cables available, ICC strongly recommends using only high-quality cables from reputable manufacturers to guarantee optimal noise immunity and cable longevity. Ensure that each end of the cable is fully seated into the modular connectors, and route the cable such that it is located well away from any drive input power or motor wiring. Also take care to route the cable away from any sharp edges or positions where it may be pinched.

8. Reinstall the drive’s front cover / close the drive’s cabinet door.

9. Repeat steps 2-8 to connect other drive(s) as needed.

10. Connect the Modbus Plus network to the “NETWORK” DB9 connector. Be sure to follow all published guidelines pertaining to Modbus Plus network connections, layout and routing.

11. If an auxiliary power supply is going to be used, connect it to the gateway’s “POWER” jack.

12. Take a moment to verify that the gateway and all network cables have sufficient clearance from drives, motors, or power-carrying electrical wiring.

13. Turn the power sources to all connected drives ON, and verify that the drives function properly. If the drives do not appear to power up, or do not function properly, immediately turn power OFF. Repeat steps 2 and 3 to remove all power from the drives. Then, verify all connections. Contact

ICC or your local Toshiba representative for assistance if the problem persists.

4.2.2 Installation for S7, S9, S11, A7 and VF-nC1 ASDs

1. Mount the unit via the desired method (refer to page 12 for more information).

CAUTION! Verify that all input power sources to the drives to

be connected have been turned OFF and are locked and tagged out.

3. DANGER! Wait at least 5 minutes for the drive’s

electrolytic capacitors to discharge before proceeding to the next step. Do

continuing the installation process.

4. Remove the drive’s common serial communication port cover if it has one (refer to the appropriate drive manual for instructions how to do this). Do not discard this cover, as it should be reinstalled to minimize contamination of the port’s electrical contacts if the gateway is ever disconnected from the drive.

5. Connect the drive’s common serial communication port to one of the ASD channels of the gateway with the communication cable (communication cable is not included with the gateway kit). When choosing cables for this connection, standard 24 AWG category 5 (CAT5) unshielded twisted-pair (UTP) 8-conductor cables found in Ethernet networks in most office environments can be used. The maximum allowable length for these cables is 5 meters. Although there are many varieties and styles of CAT5 UTP cables available, ICC strongly recommends using only high-quality cables from reputable manufacturers to guarantee optimal noise immunity and cable longevity. Ensure that each end of the cable is fully seated into the modular connectors, and route the cable such that it is located well away from any drive input power or motor wiring. Also take care to route the cable away from any sharp edges or positions where it may be pinched.

6. Repeat steps 2-5 to connect other drive(s) as needed.

7. Connect the Modbus Plus network to the “NETWORK” DB9 connector. Be sure to follow all published guidelines pertaining to Modbus Plus network connections, layout and routing.

8. If an auxiliary power supply is going to be used, connect it to the gateway’s “POWER” jack.

9. Take a moment to verify that the gateway and all network cables have sufficient clearance from drives, motors, or power-carrying electrical wiring.

10. Turn the power sources to all connected drives ON, and verify that the drives function properly. If the drives do not appear to power up, or do not function properly, immediately turn power OFF. Repeat steps 2 and 3 to remove all power from the drives. Then, verify all connections. Contact ICC or your local Toshiba representative for assistance if the problem persists.

5. RS485 Port Electrical Interfaces

In order to ensure appropriate network conditions (signal voltage levels, etc.) when using the gateway’s RS485 port, some knowledge of the network interface circuitry is required. Refer to Figure 6 for a simplified network schematic of the RS485 interface circuitry. Note that the “Shield” terminal has no internal connection: its purpose is simply to provide a cable shield chaining location between devices. The shield is then typically connected to ground at one location only.

Figure 6: RS485 Interface Circuitry Schematic

Figure 7 details the specific network connections to the RS485 terminal block.

Signal Ground

Shield

Figure 7: RS485 Terminal Block Connections

6. Environmental Specifications

Item Specification

Operating Environment

Indoors, less than 1000m above sea level, do not expose to direct sunlight or corrosive / explosive gasses

Operating Temperature

-10 ∼ +50°C (+14 ∼ +122°F)

Storage Temperature

-40 ∼ +85°C (-40 ∼ +185°F)

Relative Humidity

20% ∼ 90% (without condensation)

Vibration

5.9m/s

{0.6G} or less (10 ∼ 55Hz)

Grounding Non-isolated, referenced to power source ground

Cooling Method Self-cooled

7. Maintenance and Inspection

Preventive maintenance and inspection is required to maintain the gateway in its optimal condition, and to ensure a long operational lifetime. Depending on usage and operating conditions, perform a periodic inspection once every three to six months. Before starting inspections, disconnect all power sources.

Inspection Points

• Check that the network cable(s) are properly terminated in the terminal block(s), and ensure that pluggable terminal blocks are fully seated in their headers. Reseat if necessary.

• Check that there are no defects in any attached wire terminal crimp points. Visually check that the crimp points are not damaged or loose.

• Visually check all wiring and cables for damage. Replace as necessary.

• Clean off any accumulated dust and dirt.

• If use of the gateway is discontinued for extended periods of time, apply

power at least once every two years and confirm that the unit still functions properly.

• Do not perform hi-pot tests on the gateway, as they may damage the unit.

Please pay close attention to all periodic inspection points and maintain a good operating environment.

8. Storage and Warranty

8.1 Storage

Observe the following points when the gateway is not used immediately after purchase or when it is not used for an extended period of time.

• Avoid storing the unit in places that are hot or humid, or that contain large quantities of dust or metallic dust. Store the unit in a well-ventilated location.

• When not using the unit for an extended period of time, apply power at least once every two years and confirm that it still functions properly.

8.2 Warranty

The gateway is covered under warranty by ICC, Inc. for a period of 12 months from the date of installation, but not to exceed 18 months from the date of shipment from the factory. For further warranty or service information, please contact Industrial Control Communications, Inc. or your local distributor.

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ICC MBP-100, NETWORK GATEWAY MBP-100 Instruction Manual

Specifications and Main Features

Frequently Asked Questions

User Manual