Opto22 E1, E2 User Manual

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E1 AND E2 USER’S GUIDE

Form 1563-220304—March 2022

43044 Business Park Drive • Tem ec ula • CA 92590-3614

Phone: 800-321-OPTO (6786) or 951-695-3000

Fax: 800-832-OPTO (6786) or 951-695-2712

www.opto22.com

Product Support Services

800-TEK-OPTO (835-6786) or 951-695-3080

Fax: 951-695-3017

Email: support@opto22.com

Web: support.opto22.com

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E1 and E2 User’s Guide Form 1563-220304—March 2022

The information in this manual has been checked carefully and is believed to be accurate; however, Opto 22 assumes no responsibility for possible inaccuracies or omissions. Specifications are subject to change without notice.

Opto 22 warrants all of its products to be free from defects in material or workmanship for 30 months from the manufacturing date code. This warranty is limited to the original cost of the unit only and does not cover installation, labor, or any other contingent costs. Opto 22 I/O modules and solid-state relays with date codes of 1/96 or newer are guaranteed for life. This lifetime warranty excludes reed relay modules, groov and SNAP serial communication modules, SNAP PID modules, and modules that contain mechanical contacts or switches. Opto 22 does not warrant any product, components, or parts not manufactured by Opto 22; for these items, the warranty from the original manufacturer applies. Refer to Opto 22 form 1042 for complete warranty information.

Wired+Wireless controllers and brains are licensed under one or more of the following patents: U.S. Patent No(s). 5282222, RE37802, 6963617; Canadian Patent No. 2064975; European Patent No. 1142245; French Patent No. 1142245; British Patent No. 1142245; Japanese Patent No. 2002535925A; German Patent No. 60011224.

Opto 22 FactoryFloor, groov, groov EPIC, groov RIO, mobile made simple, The Edge of Automation, Optomux, and Pamux are registered trademarks of Opto 22. Generation 4, groov Server, ioControl, ioDisplay, ioManager, ioProject, ioUtilities, mistic, Nvio, Nvio.net Web Portal, OptoConnect, OptoControl, OptoDataLink, OptoDisplay, OptoEMU, OptoEMU Sensor, OptoEMU Server, OptoOPCServer, OptoScript, OptoServer, OptoTerminal, OptoUtilities, PAC Control, PAC Display, PAC Manager, PAC Project, PAC Project Basic, PAC Project Professional, SNAP Ethernet I/O, SNAP I/O, SNAP OEM I/O, SNAP PAC System, SNAP Simple I/O, SNAP Ultimate I/O, and Wired+Wireless are trademarks of Opto 22.

ActiveX, JScript, Microsoft, MS-DOS, VBScript, Visual Basic, Visual C++, Windows, and Windows Vista are either registered trademarks or trademarks of Microsoft Corporation in the United States and other countries. Linux is a registered trademark of Linus Torvalds. ARCNET is a registered trademark of Datapoint Corporation. Modbus is a registered trademark of Schneider Electric, licensed to the Modbus Organization, Inc. Wiegand is a registered trademark of Sensor Engineering Corporation. Allen-Bradley, CompactLogix, ControlLogix, MicroLogix, SLC, and RSLogix are either registered trademarks or trademarks of Rockwell Automation. CIP and EtherNet/IP are trademarks of ODVA. Raspberry Pi is a trademark of the Raspberry Pi Foundation. The registered trademark Ignition by Inductive Automation® is owned by Inductive Automation and is registered in the United States and may be pending or registered in other countries. CODESYS® is a registered trademark of 3S-Smart Software Solutions GmbH.

groov includes software developed by the OpenSSL Project for use in the OpenSSL Toolkit. (http://www.openssl.org)

All other brand or product names are trademarks or registered trademarks of their respective companies or organizations.

E1 and E2 User’s Guide

Opto 22 Your Edge in Automation.

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Table of Contents

Chapter 1: Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

E1 Brain Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

E2 Brain Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

About this Guide. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Other Documents You May Need . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

For Help . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

E1 and E2 Features and Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

E1 Brain Board Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

E2 Brain Board Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

Dimensional Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

E1 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

E2 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

LED Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

E1 LED Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

E2 LED Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

LED Blink Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Chapter 2: Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

What You Will Need. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Installing Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Mounting the Brain Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Connecting the Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Connecting the E1 and E2 to Earth Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Installing I/O Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Connecting to a Serial Network . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Wiring Serial Communications and Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Setting Jumpers (Serial Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Connecting to an Ethernet Network. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Security . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

I/O Modules and Mounting Racks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

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Chapter 3: Architecture and Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25

Communication Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Accessing E1 and E2 Brain Boards Over the internet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

System Architecture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Typical Control System Using Optomux . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Optomux Over Ethernet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Optomux Over Serial . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Control System Plus Data Acquisition via OPC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Communicating with Modbus/TCP Clients . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

PAC Project Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Building Custom Applications with the OptoMMP Protocol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Migration Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Acquiring Data Using OPC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Adding Modbus/TCP Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Chapter 4: Maintaining the E1 and E2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35

Assigning or Viewing the IP Address . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Resetting the Brain Board to Factory Defaults. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Loading New Firmware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Chapter 5: Using Modbus/TCP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Overview of Modbus/TCP Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Understanding Opto 22 and Modbus/TCP Differences . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Function Codes Supported . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Communication Packet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Exception Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Referencing I/O Points for E1 and E2 Brain Boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Configuring I/O Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Using Digital Point Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Latches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Counters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Using Analog Point Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Scaling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Maximum and Minimum Values (Peaks and Valleys) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Offset and Gain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Modbus/TCP Memory Map for E1 and E2 Brain Boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Coils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Input Registers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Holding Registers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Using Input and Holding Registers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Chapter 6: Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51

Troubleshooting Ethernet Communications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Pinging the Brain Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Accessing the Brain Board with PAC Manager . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

E1 and E2 User’s Guide

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Solving Network Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Create a Network Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Analyze Communication Packets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Have Your Network Certified . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Troubleshooting Serial Communications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Solving Common Communications Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Power Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Jumper Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Communication Wiring Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Other Tips: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

Error Codes When Using Opto 22 Optomux Driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

Errors Returned by the Brain Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

Driver Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

Other Error Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

General Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

Serial Communications Questions and Answers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

Appendix A: Serial-to-Ethernet Routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

Creating a Routing Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

Sample Routing Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

Enabling Serial-to-Ethernet Routing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

Disabling Serial-to-Ethernet Routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

Appendix B: Using the OmuxSettings File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

About the OmuxSettings File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Changing the OmuxSettings File. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Appendix C: Licensing Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71

Software Licenses Used in E1 and E2 Brain Boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

Opto 22 License Agreement for Embedded Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

GNU General Public License . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

GNU Lesser General Public License . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

Berkeley Software Distribution License . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

Opto 22 License Agreement for Embedded Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

GNU General Public License . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

GNU Lesser General Public License. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

E1 and E2 User’s Guide

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E1 and E2 User’s Guide

Page 7

Chapter 1\

E1 Brain Board

1: Introduction

E1 digital and E2 analog brain boards are intelligent I/O (input/output) processors that communicate with a host computer and also perform control functions at each point of I/O.

Designed as drop-in replacements for Opto 22’s B1 and B2 brain boards, the E1 and E2 have the same Optomux and serial network capabilities, but they offer significant new features: Ethernet support, additional protocol support, and migration and expansion opportunities. For example, you can use PAC Project™ software applications with E1 or E2 I/O systems to control, monitor, and acquire data.

E1 and E2 brain boards can communicate using Optomux over serial and Ethernet, and using Opto 22’s OptoMMP™ protocol over Ethernet. OLE for Process Control (OPC) and Modbus/TCP clients can readily obtain data from the system over Ethernet. For detailed information on protocols and system architecture, see

Chapter 3: Architecture and Communication.



E1 Brain Board

The E1 brain board is a digital-only processor that can be used with a variety of input/output (I/O) modules and mounting racks. The E1 supports up to 16 I/O modules.

In addition to On/Off control, the E1 brain board provides the following digital functions:

• Read/write to point

• Input latches

• Counters

• Pulse duration measurement

• Pulse generation

• Time delays

• Watchdog timer

For detailed descriptions of E1 features, see

“E1 and E2 Features and Specifications” on page 5.

E1 and E2 User’s Guide 1

Page 8

ABOUT THIS GUIDE

E2 Brain Board

The E2 brain board is an analog-only processor used with G1 (Standard) analog modules and G1-series mounting racks.

In addition to simple input and output, the E2 brain board provides the following analog functions:

• Read/write to point in Engineering units

• Read/write to point in counts

• Input averaging

• Minimum/maximum values

(peak/valley recording)

• High/low limit testing

• Offset and gain calculation

• Waveform generation

• Watchdog timer

For detailed descriptions of E2 features, see E1 and E2 Features and Specifications on page 5.

ABOUT THIS GUIDE

This guide shows you how to install and use E1 and E2 brain boards. This guide assumes that you have some familiarity with TCP/IP, UDP/IP, and Ethernet networking. If you are not familiar with these subjects, we strongly suggest you consult commercially available resources to learn about them before attempting to install or use these products.

If you are using Modbus/TCP for communicating with E1 and E2 brain boards, this guide assumes that you are already familiar with Modbus/TCP.

The following chapters are included in this user’s guide:

Chapter 1: Introduction—Provides a brief description of the E1 and E2 brain boards, the contents of this

guide, a list of other important documents, and how to reach Opto 22 Product Support.

Chapter 2: Installation—Details what you need to install E1 and E2 brain boards, how to mount the brain

board, and how to connect to a serial or Ethernet network.

Chapter 3: Architecture and Communication—Describes how E1 and E2 brain boards fit into your system

architecture and how to communicate with them.

Chapter 4: Maintaining the E1 and E2—Describes assigning and changing IP addresses, resetting the brain

board to factory defaults, and upgrading firmware.

Chapter 5: Using Modbus/TCP—Provides configuration information for those communicating with the E1

and E2 using Modbus/TCP.

E1 and E2 User’s Guide

Chapter 6: Troubleshooting—Provides tips for resolving difficulties you may encounter while working with

E1 and E2 brain boards.

Appendix A: Serial-to-Ethernet Routing—Presents how to set up the E1 and E2 to route data between

serial and Ethernet networks.

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CHAPTER 1: INTRODUCTION

Appendix B: Using the OmuxSettings File—Describes how to set Optomux network settings using the

OmuxSettings file.

Appendix C: Licensing Information—Presents licensing information for software components.

FOR HELP

NOTE: Email messages and phone calls to Opto 22 Product Support are grouped together and answered in the order received.

FOR HELP

If you have problems installing or using E1 and E2 brain boards and cannot find the help you need in this guide or on our website, contact Opto 22 Product Support.

Phone: 800-TEK-OPTO (800-835-6786 toll-free

in the U.S. and Canada) 951-695-3080 Monday through Friday, 7 a.m. to 5 p.m. Pacific Time

Email: support@opto22.com

Opto 22 website: www.opto22.com

When calling for technical support, you can help us help you faster if you provide the following information to the Product Support engineer:

• A screen capture of the Help > About dialog box showing software product and version (available by clicking Help > About in the application’s menu bar).

• Opto 22 hardware part numbers or models that you’re working with.

• Firmware version:

– For SNAP controllers and brains: available in PAC Manager by clicking Tools > Inspect. –For groov EPIC processors and groov RIO modules: available in groov Manage by clicking Info and

Help > About.

• Specific error messages you received.

• Version of your computer’s operating system.

• For PAC Control, PAC Display, OptoOPCServer, or PAC Manager, you may be requested to provide

additional information, such as log or dump files. You can find these files in a support files sub-folder:

a. On your Windows Desktop, double-click the PAC Project 10.4 folder. b. Double-click Support Files. c. Double-click on the appropriate shortcut to open the sub-folder containing the requested files.

E1 and E2 User’s Guide

Note: PAC Cont rol, PAC D is play, O pt oOP CS er ver, an d PAC Manager create appropriate sub-folders when they

create diagnostic log or dump files. If they have not created these files, the sub-folder may not exist; in this case, the shortcut will not work.

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E1 AND E2 FEATURES AND SPECIFICATIONS

E1 Brain Board Features

The following table shows features available on an E1 digital I/O unit depending on the protocol used.

Feature Optomux OptoMMP

Read/write to point 

Input latches 

Counters

Pulse duration measurement 

Pulse generation 

Time delays (10 ms resolution) 

Watchdog timer 

Networks

Serial (RS-422/485) 

Ethernet   

1 This protocol is also used with all PAC Project applications. 2 One latch per point is available; it can be configured as on-to-off or off-to-on. 3 Two latches per point are always available; no configuration is needed. 4 Maximum counter frequency is 400 Hz. Counters roll over at 65,535.

CHAPTER 1: INTRODUCTION





Modbus/TCP



About E1 and E2 brain boards: You can configure E1s and E2s like any other I/O unit if you have E1/E2 firmware R1.2a (and higher) and PAC Project 9.5000 (and higher). Also, if a SNAP PAC controller communicates with the E1 or E2, the controller must have PAC firmware R9.5a (or higher) to use this simplified configuration method. If you are not using these firmware and software versions (or if you prefer to use the previous method to reconfigure existing E1s or E2s), see

I/O Configuration for E1 an E2 Brain Boards (form 1576).

Each E1 feature is described below.

Read/Write to Point—The E1 can read the value of any input

or output point and turn digital output points

on or off.

Input Latches—When the value of a digital input point changes from off to on, an on-latch can be set.

While the value of the point may return to off, the on-latch remains set until cleared, as a record of the change.

Similarly, an off-latch can be set when the value of a digital point changes from on to off, and it remains set until cleared. See note 2 in the table above.

Latching is different on an E1 depending on the protocol used with the brain board. When the E1 is used with the Optomux protocol, only one latch is available and you must configure it to be an off-to-on latch or on-to-off latch. When you use an E1 with OptoMMP or Modbus/TCP, however, both types of latches are automatically available for each point, and no configuration is required.

Counters—Digital input can be used as a counter, counting the number of times the input changes from off to on.

Pulse Duration Measurement (using the Optomux protocol)—Any or all of the input points can function as pulse duration timers. Either on or off pulses can be timed with a resolution of 10 milliseconds.

Pulse Generation (using the Optomux protocol)—The E1 can be instructed to output a specific number of pulses (with programmable period) at any output point. Continuous square waves can also be generated.

E1 and E2 User’s Guide

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E1 AND E2 FEATURES AND SPECIFICATIONS

Time Delays (using the Optomux protocol)—Any or all output points can function in time delay mode. Outputs can be set to operate with four types of delays:

• Delay before turning off

• Delay before turning on

• Pulse on

• Pulse off

Time delays are programmable with a resolution of 10 milliseconds.

Watchdog Timer—You can set a watchdog timer to monitor communication with the PC or other host device. If the watchdog timer is set via the serial port, then any serial activity will trigger the watchdog (including communications to other devices). If it is set via the Ethernet port, then only Ethernet activity directed to the respective E1 or E2 will trigger the watchdog. If the watchdog isn’t triggered for the length of time set, the brain board automatically sets designated I/O points to the values you have determined. This action makes sure the process is brought to a safe state if communication fails.

E2 Brain Board Features

The following table shows features available on an E2 I/O unit depending on the protocol used.

Read/write to point in Engineering units

Read/write to point in counts

Input averaging

Minimum/maximum values (peak/valley recording)

High/low range testing

Offset and gain calculation

Waveform generation

Watchdog timer

Networks

Serial (RS-422/485)

Ethernet

1 This protocol is also used with all PAC Project applications. 2 If an ICTD or thermocouple module is used, minimum and maximum values are returned as counts.

Feature Optomux OptoMMP



 



  



  



 



 

Modbus/TCP

E1 and E2 User’s Guide

I/O Configuration for E1 an E2 Brain Boards (form 1576).

Each E2 feature is described below.

Read/Write to Point in Engineering Units (using OptoMMP)—The E2 can read the value of an input point and send a value to an output point in engineering units, such as millivolts or milliamps.

Read/Write to Point in Counts—The E2 can read the value of an input point and send a value to an output point in 12-bit counts.

This is especially useful when integrating with existing Optomux systems. The Optomux protocol will return counts in a range of 0–4095.

Page 13

CHAPTER 1: INTRODUCTION

The OptoMMP protocol returns counts based on how the E2 was configured:

• Modules configured directly as G1 modules (new method; requires E2 firmware R1.2a or higher and PAC

Project 9.5 or higher) will report counts as G1 counts (0–4095 nominal range).

• Modules configured as similar SNAP modules (old method using form 1576) will report counts as 0–

25000 or -25000 to +25000.

Input Averaging (using the Optomux protocol)—The E2 can be instructed to average the values of successive readings.

Minimum/Maximum Values (peak/valley recording)—The E2 automatically keeps track of minimum and maximum count values for each input. You can read these values at any time, and you can reset min/max values.

NOTE: The values returned for temperature modules will be counts, not linearized temperature values. See Read/Write to Point in Counts, above, for count values.

High/Low Range Testing—The E2 tests for the high and low limits (range) for the specified input points, and sets a flag if values exceed the specified range

Offset and Gain Calculations—The brain board can calculate offset and gain for analog input points. If a 0 VDC to +5 VDC input receives signals that are slightly off (not exactly 0 VDC at the lowest point, for example), the offset and gain can be calculated so that values will appear accurately.

NOTE: To calibrate analog points, use PAC Manager. See form #1714, the Legacy Edition PAC Manager User’s Guide.

Waveform Generation (using Optomux)—Square waves, triangle waves, and ramps can be generated at any output point with programmable rates.

E1 and E2 User’s Guide

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E1 AND E2 FEATURES AND SPECIFICATIONS

Specifications

Power Requirements

Ethernet Network Interface:

Type Connector Rate Supported Protocols

Maximum Segment Length

Serial Network Interface:

Type Connector Data Rates Supported Protocols Network Range

Optomux I/O Functions

Modbus/TCP, OptoMMP, and OPC I/O Functions

5.0–5.2 VDC @ 0.5 amps (excludes digital and analog module power requirements) *

IEEE 802.3 network, 10Base-T/100Base-TX RJ-45: Supports Auto MDI-X (crossover cable not needed) 10/100 Mbps, half or full duplex Optomux over Ethernet, Modbus/TCP, OptoMMP (Opto 22’s IEEE 1394-based memory-mapped protocol) 100 m (328 ft.) with Category 5 or superior UTP

RS-422/485 serial link E1: Terminal block; E2: Terminal block (on mounting rack) 300, 600, 1200, 2400, 4800, 9600, 19200, and 38400 baud Optomux Up to 32 Optomux stations configured for multidrop can be used on a serial network of up to 1524 m (5000 ft.) total length. Up to 256 Optomux stations and longer line lengths can be used by installing network repeaters. Up to 256 Optomux stations configured for repeat mode can exist on a network.

Digital I/O (E1): Read Point, Write Point, Latch Point (On/Off), Count, Pulse Duration, Time Delay, Pulse Generation, Watchdog Timer Analog I/O (E2): Read Point, Write Point, Input Averaging, Min/Max Recording (peak and valley), High/Low Range Testing, Offset and Gain Calculation, Waveform Generation, Watchdog Timer

With these protocols, the following brain-based features are not available:

• No pulsing or time delay (E1)

•

No pulse measurement

• No input averaging or waveform generation (E2)

LED Indicators Status, Link, Activity, Full duplex, Transmit (serial), Receive (serial)

Jumper-selectable Serial Options

Operating Temperature 0 °C to 70 °C

Storage Temperature –40 °C to 85 °C

Humidity 0–95% humidity, non-condensing

Agency Approvals DFARS

Warranty 30 months

* ±15 VDC ±0.25 V is required for the analog modules. Current depends on the number and types of modules installed. A 24 VDC power supply is required for analog modules that need a current loop source.

Group A: Multidrop or repeat mode, RS-485 termination and biasing Group B: Serial address (0 to 255), baud rate, 2- or 4-pass protocol

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Page 15

Dimensional Drawings

E1 Dimensions

CHAPTER 1: INTRODUCTION

E2 Dimensions

E1 and E2 User’s Guide

Page 16

LED DESCRIPTIONS

ACT LINK STAT

REC XMT

FDPX

ACT

LINK

STAT XMT RCV

LED DESCRIPTIONS

E1 LED Descriptions

LED Description

FD Full Duplex Mode Ethernet

ACT Network Activity Ethernet

LINK Link Ethernet

STAT Status n/a

REC Data Receive Serial

XMT Data Transmit Serial

E2 LED Descriptions

LED Description

LINK Network Link Ethernet

ACT Network Activity Ethernet

FDPX Full Duplex Mode Ethernet

STAT Status n/a

XMT Data Transmit Serial

RCV Data Receive Serial

Link

Typ e

Link

Typ e

E1 and E2 User’s Guide

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CHAPTER 1: INTRODUCTION

Status

LED

E1 Brain Board E2 Brain Board

LED Blink Codes

The Status LED (STAT) on E1 and E2 brain boards provides both event and status information.

Code Typ e Meaning Comments

3 short blinks Event

6 short blinks Event

LED on Status

LED flashing Status

The brain board is beginning to start up.

The brain board is entering loader mode.

The brain board is running.

The brain board is restoring the factory defaults or updating the firmware.

The LED starts to blink after the E1 or E2 is turned on or a reboot command is sent to the device.

The LED starts to blink after the E1 or E2 is turned on or a reboot command is sent to the device with the Loader Mode Jumper installed.

Once the brain board has started, the LED turns on and stays on. This should occur shortly after a series of 3 short blinks. Note that the color of the LED doesn't matter; as long as the LED is On and not blinking, the brain board is functioning normally.

CAUTION: DO NOT turn off power to the device while the LED is flashing, even if it takes a very long time. Turning off power might corrupt the firmware and the brain board will not be able to start up. For more information, see

“Resetting the Brain Board to Factory Defaults” on page 35 and “Loading New Firmware” on page 36.

E1 and E2 User’s Guide

Page 18

LED DESCRIPTIONS

E1 and E2 User’s Guide

Page 19

Chapter 2

2: Installation

Use this chapter to install E1 and E2 brain boards. If you need more information on how to integrate E1s and E2s with your system, see Chapter 3: Architecture and Communication.

WHAT YOU WILL NEED

To install an E1 or E2, you need the following items:

• PC running Microsoft

protocol installed, and a valid IP address. The PC must be on the same subnet as the brain board.

• Serial cable for a serial network. For an Ethernet network, use Category 5 Ethernet cable. (For more

information on cables, see page 22.)

• E1 or E2 brain board

• I/O modules and mounting racks (See compatible I/O modules and mounting racks on page 22.)

• Power supply (See page 23.)

• Voltmeter

• Screwdriver

Windows® 2000 or higher, with a 10/100 MB Ethernet adapter card, the TCP/IP

INSTALLING SOFTWARE

The software for E1 and E2 brain boards is available on the Opto 22 website.

• The E1 product page lists all E1 software in the Downloads tab.

• The E2 product page lists all E2 software in the Downloads tab.

MOUNTING THE BRAIN BOARD

Racks vary in shape and design. The combination of rack, modules, and brain board (called the I/O unit) can be mounted in any attitude on any flat surface.

To ensure reliable and trouble-free communications, the following is recommended:

• Use twisted-pair wires for the serial communications wiring. See page 22.

• Keep communication and DC power wiring separate from any high-voltage field wiring.

Steps for mounting:

1. If you are replacing an existing B1 or B2 brain board, turn off the power to the rack and carefully remove

the B1 or B2 from the rack.

2. Carefully plug the E1 or E2 brain board into the mounting rack using the 50-pin connector.

E1 and E2 User’s Guide 13

Page 20

MOUNTING THE BRAIN BOARD

E1 brain board/rack combination. As shown in the G1/Standard example below, the brain board extends out past the end of the rack when used with G4, G1, and Quad Pak I/O racks. For integral racks, which have permanent I/O circuitry built in, the brain board is inserted in the other direction, covering the rack.

E2 brain board/rack combination

3. Place the I/O unit as close as possible to the controlled device to minimize wiring costs and noise for

analog modules. When installing units next to each other, leave sufficient space between units for wiring.

4. For maximum physical strength, secure the brain board’s permanently attached standoffs. Also secure standoffs on the rack, if available.

E1 and E2 User’s Guide

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CONNECTING THE POWER SUPPLY

CHAPTER 2: INSTALLATION

1. Using size 14 AWG or larger wire, connect 5-volt power to the + 5V and GND connectors on the

mounting rack. If the + 5-volt supply is used by more than one unit or by other devices, make sure the voltage at each rack is 5.1–5.2 VDC. Use a consistent color code from the power supply to all brain boards to prevent wiring errors. See Opto 22 form #1271, Using Power Supplies with Opto 22 Systems, for more information on power wiring and voltage adjustments.

EXCEPTION: If an Opto 22 PBSA/B/C power supply is used with digital racks, the + 5 VDC logic connection is made by the supply when it is screwed to the rack. In this case, the only connection required is the 120 VAC (220 VAC or 10–28 VDC depending on supply type) connection to the PBSA (or PBSB or PBSC) supply.

2. You can use either separate or combined 5.1–5.2 VDC and ± 15 VDC (± 0.25 VDC) supplies to provide

power to analog racks. If you use a multiple-output supply, make sure that the 5 VDC RETURN line is separate from the 15-volt COMMON line to maintain module isolation.

3. Route the +5-volt and ±15-volt wires away from any high-voltage field wires. Make sure there is only one

earth ground connection per network, typically at the host site. If the ground connection is at the host site, make sure none of the power supplies is grounded. This

method prevents ground loop problems due to offset voltages appearing between multiple ground points.

4. IMPORTANT: Check polarities of all power supply connections before applying power.

Incorrect polarity can damage the brain board and I/O modules.

NOTE: If the brain board is connected to an Ethernet network, before powering up see the section about assigning an IP address in form #1714, Legacy Edition PAC Manager User’s Guide.

E1 and E2 User’s Guide

Page 22

CONNECTING THE E1 AND E2 TO EARTH GROUND

E1 grounding PEM E2 grounding PEM

CONNECTING THE E1 AND E2 TO EARTH GROUND

In installations where electrical noise is a concern, the E1 and E2 each provide a grounding point to improve noise immunity. Using 18 AWG, connect the insulated wire from the grounding PEM to the point where the earth ground is connected. Each brain should have a separate wire to connect to ground. Each grounding point should be tied to a single point earth ground.

INSTALLING I/O MODULES

1. Turn off all power to the unit and to the field devices. IMPORTANT: All power must be turned off before installing or removing I/O modules.

2. Install input and output modules in any rack position. Compatible modules are shown in the table on

page 22. For specifications and wiring information on modules, see the module’s data sheet.

3. Depending on the networks you are using, continue with the following: – “Connecting to a Serial Network,” below – “Connecting to an Ethernet Network” on page 21

NOTE: You can use both serial and Ethernet networks simultaneously. E1 and E2 brain boards are set by default to communicate on both networks.

CONNECTING TO A SERIAL NETWORK

Wiring Serial Communications and Power

A complete connection at each brain board consists of 10 wires as well as an overall cable shield: two twisted pairs and a common coming from the computer or previous brain board, and two twisted pairs and a common going to the next brain board. To ensure reliable communications, we recommend the following:

• Use shielded twisted-pair wires for the communications wiring. (See recommended cables on page 22.)

• Route the communication and DC power wiring separately from any high-voltage field wiring or AC

power wiring.

• Make sure the communications COM terminals on each rack are connected.

E1 and E2 User’s Guide

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CHAPTER 2: INSTALLATION

The following graphic shows standard and alternate wiring diagrams. When wiring a series of brain boards, always think of the previous brain board as the host.

Setting Jumpers (Serial Only)

Jumpers in groups A and B are set during initial configuration:

• Group A jumpers set repeat or multidrop mode, and termination.

• Group B jumpers set baud rate, 2-pass or 4-pass message, and address.

For an easy way to see which jumpers to set, go to our website and use the E1/B1 Brain Jumper Configurator or the E2/B2 Brain Jumper Configurator.

Note: If you have an existing brain and need to know how it is currently configured (for example, if you are replacing a B1 with an E1 and need to configure them the same), use these interactive demos:

Jumper Settings

or Read E2/B2 Jumper Settings.

E1 and E2 User’s Guide

Read E1/B1

Page 24

CONNECTING TO A SERIAL NETWORK

Group A

E1 Brain Board

jumpers

Group B jumpers

Group A jumpers

Group B jumpers

E2 Brain Board

For information on using jumpers to reset the brain board, see “Resetting the Brain Board to Factory Defaults”

on page 35.

Also see “Jumper Tips” on page 54.

NOTE: When the E1 or E2 is powered up, it periodically reads the jumpers. You can change the jumpers at any time and the firmware will detect the change and reconfigure accordingly.

1. Set the jumpers in Group A for repeat or multidrop mode, and proper termination and biasing.

Multidrop—When wiring a multidrop communications cable, keep in mind that the cable is a

high-speed data-transmission line. To reduce reflections, make sure the line is terminated properly at both ends and that all stubs are less than three inches long.

Repeat—In this configuration, each brain board acts as a repeater, allowing up to 5,000 feet between units. Since a power failure at any unit breaks the communications link, battery backup is recommended.

NOTE: You cannot mix units operating in repeat mode and units operating in multidrop mode on the same network.

E1 and E2 User’s Guide

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CHAPTER 2: INSTALLATION

Baud Rate

Message

Address

Group B Jumpers

Protocol

JumperBaud Rate

Protocol Jumper

2. Set the Group B jumpers, including baud rate, message protocol, and address.

a. Select the baud rate using jumpers 8, 9, and 11 in Group B. Make sure to set all brain boards on the

same network at the same baud rate.

b. Set the message protocol using jumper 10 in Group B for 2-pass or 4-pass. Make sure all brain

boards on the same network use the same message protocol.

Use 2-pass for normal operation. It provides more efficient and faster communications. For a detailed description of 2-pass and 4-pass modes, see form # 1572, the Optomux Protocol Guide.

E1 and E2 User’s Guide

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CONNECTING TO A SERIAL NETWORK

c. Set the address using jumpers 0–7 on Group B, according to the following chart. Each brain board

on the same network must have a unique address. Addresses do not need to be sequential.

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CONNECTING TO AN ETHERNET NETWORK

Group A

E1 Brain Board

jumpers

Group B jumpers

Group A jumpers

Group B jumpers

E2 Brain Board

Group A Jumpers Set for Multidrop Mode/ Middle of Link

0Out

5Out

6Out

7Out

8Out

9Out

To connect to an Ethernet network, see form #1714, the PAC Manager User’s Guide, Legacy Edition.

IMPORTANT: If you are communicating only on an Ethernet network (no serial connections), make sure that

Group A jumpers on E1 and E2 brains are set for multidrop mode/middle of link (see diagram below).

If jumpers are not set in this way, the RS-485 communication lines may cause interference.

CHAPTER 2: INSTALLATION

Security

When designing your Ethernet network, be sure to consider security as required for your application. You can use PAC Manager to limit access to Ethernet-based I/O units, either by allowing access only from specific computers or other devices on the network (IP filtering), or by limiting access to specific protocols that are used with the I/O unit (port access).

See form #1714, the Legacy Edition PAC Manager User's Guide, for more information on security.

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SYSTEM COMPONENTS

This section gives additional information on some items listed in “What You Will Need” on page 13.

I/O Modules and Mounting Racks

The brain board plus the mounting rack and modules are often referred to as the I/O unit. Choose compatible I/O modules and mounting racks from the following tables.

I/O modules Digital mounting racks I/O modules Analog mounting racks

E1 (Digital) E2 (Analog)

G4 Digital I/O

Quad Pak PB16HQ

Standard (G1) I/O

Combination I/O and rack (Integral racks)

G4PB16J/K/L PB16J/K/L

G4PB8H G4PB16H G4PB16HC

PB4H PB8H PB16H PB16HC

Standard (G1)

PB4AH PB8AH PB16AH

Cable

For serial (RS-422/485) communications, the following cables are recommended. Cables listed are 24-gauge, 7x32 stranded, with 100-ohm nominal impedance and a capacitance of 12.5 pF/ft. If you use other cables, they should have a nominal impedance of 100–120 Ohms and a capacitance of less than 15 pF/ft.

We also recommend that you choose a cable with one more pair than your application requires, so you can use one of the extra wires, rather than the shield, for the signal common.

Four-pair Three-pair

• Belden P/N 8104 (with overall shield)

• Belden P/N 9728 (individually shielded)

• Belden P/N 8164 (individually shielded with overall shield)

• Manhattan P/N M3477 (individually shielded with overall shield)

• Manhattan P/N M39251 (individually shielded with overall shield)

• Belden P/N 8103 (with overall shield)

• Belden P/N 9730 (individually shielded)

• Belden P/N 8163 (individually shielded with overall shield)

• Manhattan P/N M3476 (individually shielded with overall shield)

• Manhattan P/N M39250 (individually shielded with overall shield)

For Ethernet communications, use a Category 5 Ethernet connection to a standard 10BASE-T or 100BASE-TX Ethernet network. If you need a direct connection to a PC, use an Ethernet crossover cable.

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CHAPTER 2: INSTALLATION

Power Supply

Choose the power supply appropriate for the rack. E1 and E2 brain boards require 5.0–5.2 VDC at 0.5 amps (see note). Although it is possible to distribute DC from a common power supply to several locations, better noise immunity is obtained by having separate power supplies for each I/O unit. For more information, see Opto 22 form #1271, Using Power Supplies with Opto 22 Systems Technical Note.

NOTE: For all Opto 22 products that require 5 VDC, we recommend adjusting the power supply so that the Opto 22 products are receiving 5.10 –5.20 VDC. This recommendation is based on years of experience and will eliminate many startup and maintenance issues.

Analog racks also require +15 VDC and -15 VDC (± 0.25 VDC) to power the analog I/O modules. The amount of power required depends on the type and number of analog I/O modules that are plugged into the rack. Power requirements for each of the analog modules are included in the module specifications.

Analog racks also provide terminals for a separate +24 volt supply that can be used for powering 4–20 mA current loops using 4–20 mA analog I/O modules. For this type of application, the +24 volt supply is required in addition to the supplies mentioned above. Refer to the module data sheets for information on wiring 4–20 mA modules with a loop supply.

The current requirements given for the output modules are only for the modules. To determine what size power supply is needed, add the load requirements for each module to determine total power supply requirements.

NOTE: Use only isolated supplies. Isolated supplies reduce the risk of ground loops in the communication wiring. Do not connect the power supply’s DC common to earth ground. Linear power supplies are recommended. See Opto 22 form #1271, for more information.

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SYSTEM COMPONENTS

E1 and E2 User’s Guide

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Chapter 3

3: Architecture and Communication

This chapter describes the options you have for communicating with E1 and E2 brain boards, illustrates system architecture for the E1 and E2, and discusses options to change from serial B1 or B2 systems to E1 or E2 Ethernet systems.

It includes the following topics:

Communication Options (below)

System Architecture page 26

Migration Options page 32

COMMUNICATION OPTIONS

Each E1 and E2 can communicate with a host through its serial port, its Ethernet port, or both, using a variety of protocols. The Optomux protocol can be used on both serial and Ethernet networks; other protocols are also available on Ethernet. You can use all of the Ethernet and serial protocols shown in the table below simultaneously.

The protocols and networks have specific advantages and disadvantages, summarized below.

Protocol &

Network

Optomux over Ethernet

OPC over Ethernet

Modbus/TCP over Ethernet

OptoMMP over Ethernet

Optomux over serial

* No pulsing or time delay on E1; no input averaging or waveform generation on E2.

All possible brain board features are available. Ethernet network allows multiple hosts and more than 256 I/O units.

OPC clients communicate to E1 and E2 via OptoOPCServer. Can be used simultaneously with Optomux control software running over Ethernet or serial.

E1 and E2 become part of a Modbus/TCP system. Can be used simultaneously with Optomux control software running over Ethernet or serial.

E1 and E2 can be part of an PAC Project control system. Custom applications can be built for E1, E2, and other Opto 22 memory-mapped devices, such as SNAP PAC brains. Ethernet network allows multiple hosts and more than 256 I/O units.

All Optomux protocol features are available.

Advantages Disadvantages See

Brain board features are somewhat limited.*

Limited to one host and 256 I/O units. Host must be on the serial network.

page 27

page 28

page 29

PAC Project:

page 29

OptoMMP:

page 31

page 32

E1 and E2 User’s Guide 25

Page 32

SYSTEM ARCHITECTURE

Accessing E1 and E2 Brain Boards Over the internet

Since E1 and E2 brain boards operate like any other device on an Ethernet network, you can access them over the internet in exactly the same way you would access a computer. Remote monitoring, data acquisition, and control applications can communicate with the brain boards over the internet. The details of doing so depend on your network and internet connection.

Consult your system or network administrator or your Internet Service Provider (ISP) for more information.

SYSTEM ARCHITECTURE

E1 and E2 brain boards provide processing power for Opto 22 input/output (I/O) modules. E1 brain boards support digital I/O modules, and E2 brain boards support analog modules.

Digital—The E1 can be used with single-point G4 or G1 modules, four-point Quad Pak modules, or integral racks (digital I/O built into the rack).

Analog—The E2 can be used with single-point G1 modules.

The combination of brain board, I/O modules, and mounting rack is often referred to as an I/O unit.

Because E1 and E2 brain boards communicate over both serial and Ethernet networks, you can use them for remote monitoring, data acquisition, and industrial control using Optomux, OptoOPCServer, Modbus/TCP, and software applications built with Opto 22’s PAC Project software suite (requires an Opto 22 SNAP PAC industrial controller). OPC and PAC Project applications use Opto 22’s memory-mapped protocol, OptoMMP.

The following sections include information and architectural diagrams illustrating these uses.

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CHAPTER 3: ARCHITECTURE AND COMMUNICATION

Host controlling system using Optomux protocol over Ethernet network

Ethernet network

Typical Control System Using Optomux

Optomux Over Ethernet

A control system using the Optomux protocol and running over an Ethernet network is a typical use for E1 and E2 brain boards. E1s and E2s use UDP for Ethernet communication.

Here is an example of such a system:

Optomux Over Serial

Since E1 and E2 brain boards also support RS-422/485 serial networks, they can communicate using the Optomux protocol over serial. Programming information for this use is in Opto 22 form #1572, the Optomux Protocol Guide.

E1 and E2 User’s Guide

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SYSTEM ARCHITECTURE

Host collecting data using OPC

Ethernet network

Host controlling system using

Optomux protocol over

Ethernet network

Control System Plus Data Acquisition via OPC

Use OptoOPCServer to provide communication between E1 and E2 brain boards and OPC clients. OptoOPCServer is a fast, efficient OLE for Process Control (OPC) 2.0-compliant server available for purchase through Opto 22’s distributors or on Opto 22’s website, www.opto22.com. Documentation for the server is included.

A control system that’s also serving data to OPC clients might look like this:

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CHAPTER 3: ARCHITECTURE AND COMMUNICATION

Ethernet network

Modbus/TCP hardware or software

Communicating with Modbus/TCP Clients

Complete information to communicate with Modbus/TCP clients is in Chapter 5: Using Modbus/TCP. Here is an example of system architecture:

PAC Project Control System

E1 and E2 brain boards can be used as part of a complete SNAP PAC System, with an Opto 22 SNAP PAC programmable automation controller, SNAP I/O units, and control and HMI applications you have built using the PAC Project Software Suite. The suite comes in two forms: PAC Project Basic™ and PAC Project Professional™.

PAC Pr o j e c t Basic is free from our website, www.opto22.com, and includes:

• PAC Control™, a flowchart-based programming tool for machine control and process applications. You build the control strategy, download it to a SNAP PAC industrial controller, and it runs independently on the controller.

•PAC Display™, an HMI package for building operator interfaces for your Microsoft clients. PAC Display includes alarming, trending, security, and a built-in library of industrial graphics.

•PAC Manager™, a utility application used to assign IP addresses, configure I/O points and I/O unit features, and inspect, read from, or write to I/O units.

PAC Project Professional is available for purchase from our distributors or on Opto 22’s website. The Pro version

adds:

•OptoOPCServer™, a fast, efficient OPC 2.0-compliant server.

• OptoDataLink™, for exchanging data with common databases such as Microsoft SQL Server® and

MySQL®.

• Support for legacy mistic I/O units, redundant controllers, and complex networks.

Windows®-based

E1 and E2 User’s Guide

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SYSTEM ARCHITECTURE

SNAP PAC industrial controller running PAC Co ntro l s trate gy

PC used to develop PAC Control strategy

PC running PAC Display HMI for operator

OptoOPCServer providing OPC data to any OPC client

E1 with G4 modules

E2 with G1 modules

SNAP PAC brain with SNAP 4-channel digital modules

SNAP PAC brain with analog, 32-channel digital, and serial modules

Ethernet network

Complete documentation is included with the software suite. For E1s and E2s, use the Legacy Editions of all guides; for example, PAC Control User’s Guide, Legacy Edition (form #1710); PAC Control Command Reference, Legacy Edition (form #1711); and PAC Manager User’s Guide, Legacy Edition (form #1714).

An example of a SNAP PAC System incorporating E1s and E2s is shown below.

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CHAPTER 3: ARCHITECTURE AND COMMUNICATION

Building Custom Applications with the OptoMMP Protocol

If you do not want to use Optomux and are not using an Opto 22 controller, you can communicate with the E1 and E2 over Ethernet using custom applications you have written with OptoMMP, Opto 22’s memory-mapped protocol. This protocol is open and documented, one for C++ and one for .NET. Both are available on our website:

• C++ OptoMMP Software Development Kit for groov EPIC and SNAP PAC

• .NET OptoMMP Software Development Kit for groov EPIC and SNAP PAC

NOTE: Some E1 and E2 features are available only using Optomux. For details, see “E1 and E2 Features and

Specifications” on page 5

OptoMMP is the same protocol used with all current Opto 22 Ethernet-based hardware and software. Therefore, custom applications you build using OptoMMP can consolidate E1s and E2s with SNAP Ethernet-based systems, and applications you may have already built for SNAP Ethernet-based systems can be easily expanded to include E1s and E2s.

Documentation for each SDK is included in the kit. Opto 22 form #1465, the OptoMMP Protocol Guide, provides complete documentation of the memory map.

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MIGRATION OPTIONS

E1 and E2 brain boards provide processing power for I/O just like their predecessors, the B1 and B2 brain boards. Designed as drop-in replacement boards for the B1 and B2, the E1 and E2 have the same Optomux and serial network capabilities, but also add significant features: Ethernet support, additional protocol support, and migration and expansion opportunities.

Since the E1 and E2 were designed to be interchangeable with existing B1s and B2s, you can simply remove an older brain board from the rack and replace it with an E1 or E2. Your Optomux application will run on the E1 or E2 without any software changes.

With its additional capabilities, however, the E1 or E2 is ideal for migrating to newer networks, hardware, and software applications, as it has the flexibility to work with both older and newer networks and protocols.

If you are using E1 or E2 brain boards to migrate from an existing Optomux system using B1 or B2 brain boards, the protocol and network you choose are determined by your goals for the system. The following table shows how to accomplish specific migration goals with the E1 and E2 and refers you to sources for more information.

Your goal

Keep existing software running over serial. Add Ethernet capability so you can acquire data from the system using OPC.

Keep existing software running over serial. Add Ethernet capability so that Modbus/TCP clients can communicate with the system.

Keep existing software running over serial. Add Ethernet capability so you can extend the system beyond serial network physical limitations.

Replace serial network with Ethernet network, but continue using Optomux protocol.

Replace serial network with Ethernet network. Use PAC Project with an Opto 22 industrial controller to control the system.

Hardware and network

changes

Replace B1s and B2s with E1s and E2s, keeping same racks and I/O. Keep serial network; add Ethernet network and OPC host computer.

Replace B1s and B2s with E1s and E2s, keeping same racks and I/O. Keep serial network; add Ethernet network.

Replace B1s and B2s with E1s and E2s, keeping same racks and I/O. Retire serial network except for first link; add Ethernet network.

Replace B1s and B2s with E1s and E2s, keeping same racks and I/O. Replace network.

Replace B1s and B2s with E1s and E2s, keeping same racks and I/O. Replace network. Add SNAP PAC controller. (Optional) Expand system to include SNAP hardware.

Software changes See

Existing software continues to run over serial. Use OptoOPCServer to acquire system data from E1s or E2s over Ethernet.

Existing software continues to run over serial. Use Modbus/TCP to communicate with E1s or E2s over Ethernet.

Existing software continues to run over serial. Configure first E1 or E2 as a serial-to-Ethernet router.

Modify or replace current software using the Optomux Protocol Driver.

Replace current control software with software built using PAC Control (Optional) Add an HMI or OPC support using other PAC Project software applications.

™

Architecture: page 33 Programming: OptoOPCServer User’s Guide (form #1439)

Architecture: page 33 Programming: Chapter 5: Using

Modbus/TCP in this guide

Architecture and Programming: See

“A: Serial-to-Ethernet Routing” on page 61.

Architecture: page 27 Programming: Optomux Protocol Guide, form #1572

Architecture: page 29 Programming: PAC Control User’s

Guide (form #1710) and Command Reference (#1711)

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CHAPTER 3: ARCHITECTURE AND COMMUNICATION

Host collecting data using OPC

over Ethernet network

Host controlling system using Optomux over serial

ial

(

-42

2/485

)

Ethernet network

Acquiring Data Using OPC

You can use OPC to acquire data from E1 and E2 brain boards without disturbing your existing software. OptoOPCServer can serve data from E1s and E2s over Ethernet separately from the software running over the serial network.

As shown below, simply replace the existing B1s and B2s with E1s and E2s, keeping the same racks and I/O, and link the E1s and E2s to the Ethernet network. Because the new brain boards have a serial port, they work exactly like the old ones over serial, and your existing Optomux software application needs no changes.

Use OptoOPCServer (sold separately) to acquire system data from E1 and E2s over the Ethernet link, and to read and write data to E1 and E2s. See the OptoOPCServer User’s Guide (form #1439) for more information.

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MIGRATION OPTIONS

Host controlling system using Optomux over serial link

Ethernet network

(

)

Modbus/TCP hardware or software

Adding Modbus/TCP Communication

You can communicate with the E1 and E2 using Modbus/TCP over Ethernet without disturbing the existing software running over serial.

Replace the existing B1s and B2s with E1s and E2s as shown below, keeping the same racks and I/O, and attach the new brain boards to the Ethernet network. Because the E1s and E2s have a serial port with the same capabilities as the B1 and B2, your existing Optomux software application does not need to be changed.

Modbus/TCP clients can read and write to E1 and E2s over the Ethernet network. For more information, see

Chapter 5: Using Modbus/TCP.

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Chapter 4‘

4: Maintaining the E1 and E2

This chapter describes how to maintain E1 and E2 brain boards. It includes the following topics:

Assigning or Viewing the IP Address (below)

Resetting the Brain Board to Factory Defaults page 35

Loading New Firmware page 36

ASSIGNING OR VIEWING THE IP ADDRESS

Any E1 or E2 used with PAC Project software (PAC Control, PAC Display, or OptoOPCServer) or applications built with the OptoMMP Communication Toolkit or the Optomux Driver Toolkit must be assigned a static IP address, because you will use the IP address to communicate with the device. For more information about IP addresses and instructions to assign them, see the Legacy Edition PAC Manager User’s Guide, form #1714.

RESETTING THE BRAIN BOARD TO FACTORY DEFAULTS

If you need to reset an E1 or E2 brain board to factory default settings, you can do so using a jumper. When you reset the brain board, any files and configuration settings are erased. If you only need to reset points to their defaults, see the instructions in the PAC Manager User’s Guide.

NOTE: Other jumpers on the E1 and E2 (groups A and B) are used to configure the brain board. For information on setting the Group A and Group B jumpers, see

page 54

To reset the brain board to factory defaults:

1. Turn off power to the brain board and remove the Ethernet connector.

2. Using needle-nosed pliers, install a jumper as follows:

“Setting Jumpers (Serial Only)” on page 17. Also see “Jumper Tips” on

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Page 42

LOADING NEW FIRMWARE

Install jumper

on pins 3 and 4

Status LED

Pin 1

E1 Brain Board

Status LED

E2 Brain Board

Pin 1

Install jumper

on pins 3 and 4

– For the E1 brain board, use pins 3 and 4 on jumper block J5.

– For the E2 brain board, use pins 3 and 4 on jumper block J3.

LOADING NEW FIRMWARE

3. Turn on power to the brain board. The Status LED starts blinking. The Status LED is labeled STAT on the board and is shown in the graphic

above.

CAUTION: Do not turn off power to the brain board while the STAT LED is flashing! Doing so may corrupt the

brain board firmware. In most cases, you will need to wait about 5 minutes or less. However, if your brain board has version R1.1e firmware, you may need to wait a very long time, even overnight. Be patient and wait till the STAT LED stops flashing.

4. Wait until the light stops blinking and is solidly on (in approximately 30 seconds), and then turn off power to the brain board.

For more information on LEDs and blink codes, see “LED Descriptions” on page 10.

5. Remove the Reset to Factory Defaults jumper, and reconnect the Ethernet cable.

6. Before turning on power to the brain board, follow the steps in form #1714, the Legacy Edition PAC

Manager User’s Guide, to assign a new IP address.

Each E1 and E2 brain board contains firmware (sometimes referred to as the kernel), which is similar to an operating system. If the firmware should become damaged, or if a new version of the firmware is released, you can load new firmware to the E1 or E2 device using PAC Manager.

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CHAPTER 4: MAINTAINING THE E1 AND E2

IMPORTANT: Before you begin, review the E1/E2 Firmware Readme for any changes that may affect which

version of firmware to use or which version of PAC Manager software is required to update the firmware.

1. Before beginning, make sure you have the IP address(es) of the E1s and E2s that will receive the new

firmware.

2. Choose Start > Programs > Opto 22 > PAC Project Software > PAC Manager.

The PAC Manager main window opens:

3. Click the Maintenance icon .

4. If you have files on the E1 or E2 that you want to preserve, download them now.

For example, if you are using the Optomux routing capabilities and have uploaded the OmuxSettings and OmuxRoutes files to the brain, you may want to copy these files to your computer. For a description of how to do this, see step 3 on page 65.

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LOADING NEW FIRMWARE

Firmware file to load

IP addresses of brain boards to receive firmware file (Only highlighted IPs receive new firmware.)

5. Make sure Install Firmware is highlighted in the Command list.

6. If you do not have the new firmware file, click Get Latest Firmware to go to the Opto 22 website. In the

7. Click the Browse button . From the drop-down list for Files of Type, select E1/E2 Firmware (*.bin).

8. If the IP address(es) of the target E1 and E2 devices appear in the IP Addresses list, skip to step 10. (Or, if

Search Downloads field, type

E1 for E1 firmware or E2 for E2 firmware. Click the links to download the

firmware file and save it to your computer. If you have any difficulty obtaining new firmware, contact Opto 22 Product Support.

Locate the firmware file you downloaded from our website, and then double-click the filename. The Filename appears in the Filename field.

you have previously saved a list of IP addresses, click Load to load the saved list.) If the address(es) you need don’t appear in the list, click Add.

9. Enter the address or a range of consecutive addresses, and then click OK.

10. In the I/O Unit Maintenance dialog box, highlight the IP addresses to send firmware to.

The address(es) you entered appear in the I/O Unit Maintenance dialog box.

CAUTION: If you mistakenly enter the address of some other E1 or E2, you will erase the current firmware in

that device, and there is no undo. Make certain you have the correct IP addresses and that you want to download new firmware.

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CHAPTER 4: MAINTAINING THE E1 AND E2

11. Click the Execute button.

The file is loaded to the brain boards, and progress is shown in the Results area. When the file is loaded and the brain boards are automatically rebooted, a “Success” message appears.

CAUTION: Do not turn off power to the brain board while the STAT LED is flashing! Doing so may corrupt the

brain board firmware. In most cases, you will need to wait about 5 minutes or less. However, if your brain board has version R1.1e firmware before the update, you may need to wait a very long time, even overnight. Be patient and wait till the STAT LED stops flashing.

12. After installing new firmware, reconfigure all of the I/O and reset the calibration settings (offset and gain).

Also, if you are using the routing capabilities, you need to replace the OmuxSettings and OmuxRoutes files. For a description of how to do this, see Appendix A: Serial-to-Ethernet Routing.

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LOADING NEW FIRMWARE

E1 and E2 User’s Guide

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Chapter 5

5: Using Modbus/TCP

INTRODUCTION

This chapter includes instructions for using Modbus/TCP to communicate with E1 and E2 brain boards. It includes information on Modbus communication and working with I/O points, and it includes the Modbus memory map for the brain boards.

The following topics are included in this chapter:

Overview of Modbus/TCP Communication (below)

Referencing I/O Points for E1 and E2 Brain Boards page 44

Configuring I/O Points page 45

Modbus/TCP Memory Map for E1 and E2 Brain Boards page 46

This chapter assumes that you already have an understanding of Modbus/TCP programming and communications. Use this chapter in conjunction with the Open Modbus/TCP Specification and the Modicon Modbus Protocol Reference Guide, both available from Modicon, Inc., Industrial Automation Systems.

OVERVIEW OF MODBUS/TCP COMMUNICATION

Communicating with E1 and E2 brain boards using Modbus/TCP requires four basic steps: connect, configure, read/write, and disconnect. When opening a TCP/IP connection to an E1 or E2 system, you normally use port

502.

Up to eight Modbus masters or clients can be simultaneously handled by E1 and E2 brain boards. When communicating with a master, use a slave address (Unit ID) of 1 or 0 for the brain board.

Understanding Opto 22 and Modbus/TCP Differences

Notice that Opto 22 module position numbers start numbering at 0 (zero), while Modbus coil, input, and register numbers start at 1; so Modbus coil 1, input 1, or register 1 refers to the module in position 0 on the rack. To reduce confusion, use the I/O reference diagrams starting on page 44 when working with Modbus.

Also notice the differences in Opto 22 and Modbus terms:

Modbus Term Opto 22 Term Modbus Term Opto 22 Term

Coils Digital outputs Register inputs Analog inputs

Inputs Digital inputs Holding registers Analog outputs and miscellaneous

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OVERVIEW OF MODBUS/TCP COMMUNICATION

Function Codes Supported

E1 and E2 brain boards use the Modbus register number and function code to access the appropriate memory map location on the brain board.

The following table shows supported Modbus function codes:

Modbus Command

(Hex)

01 Read coil status Read digital output

02 Read input status Read digital input

03 Read holding registers Read analog output and miscellaneous

04 Read input registers Read analog input

05 Force single coil Turn on/off one digital output

06 Preset single register Write one analog output or miscellaneous

0F Force multiple coils Turn on/off multiple digital outputs

10 Preset multiple registers Write multiple analog outputs or miscellaneous

11 Report slave ID Report hardware and firmware revision levels

Definition Opto 22 Equivalent

NOTE: Command 0x11, Report slave ID, returns data bytes as shown in the following table. Bytes 1 and 2 are always in the formats shown. The 0x22 in byte 1 indicates an Opto 22 brain board; 0xFF appears in byte 2 because, since the brain board is a slave, it is always running.

The data in the following table is in hex.

Byte 1 Byte 2 Bytes 3–6 Bytes 7–10 Bytes 11–14

Slave IDRun

Indicator

22 FF 01 01 01 01 01 01 01 01 01 01 01 01

Hardware Version Firmware Version Loader Version

Month Day Year Month Day Year Month Day Year

Communication Packet

As the Modbus/TCP specification requires, E1 and E2 brain boards use a Modbus RTU packet inside TCP/IP. The Modbus checksum is not used; instead, the Ethernet TCP/IP link layer checksum guarantees data. The size of the packet is limited to 256 bytes. The packet follows the standard Modbus format and contains the following:

Byte 0 Identifier, copied by responder (usually 0)

Byte 1 Identifier, copied by responder (usually 0)

Byte 2 Protocol identifier = 0

Byte 3 Protocol identifier = 0

Byte 4 Length field (upper byte) = 0, since all messages are smaller than 256

Byte 5 Length field (lower byte) = number of bytes following

Byte 6 Unit identifier (slave address, normally 1)

Byte 7 Modbus function code (See table on page 42.)

Byte 8 and following

NOTE: You can read a maximum of 125 input or holding registers in one command 03 or 04.

Data as needed

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CHAPTER 5: USING MODBUS/TCP

Exception Errors

If an error occurs, standard Modbus exception codes are returned in the Modbus packet. See the Modicon documentation for more information.

The following table, reprinted from the Modicon Modbus Protocol Reference Guide, shows the Modbus exception codes:

Code Name Meaning

01 ILLEGAL FUNCTION

02 ILLEGAL DATA ADDRESS

03 ILLEGAL DATA VALUE

04 SLAVE DEVICE FAILURE

05 ACKNOWLEDGE

06 SLAVE DEVICE BUSY

07 NEGATIVE ACKNOWLEDGE

08 MEMORY PARITY ERROR

The function code received in the query is not an allowable action for the slave.

The data address received in the query is not an allowable address for the slave.

A value contained in the query data field is not an allowable value for the slave.

An unrecoverable error occurred while the slave was attempting to perform the requested action.

The slave has accepted the request and is processing it, but a long duration of time will be required to do so. This response is returned to prevent a timeout error from occurring in the master. The master can next issue a Poll Program Complete message to determine if processing is completed.

The slave is engaged in processing a long-duration program command. The master should retransmit the message later when the slave is free.

The slave cannot perform the program function received in the query. This code is returned for an unsuccessful programming request using function code 13 or 14 decimal. The master should request diagnostic or error information from the slave.

The slave attempted to read extended memory, but detected a parity error in the memory. The master can retry the request, but service may be required on the slave device.

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REFERENCING I/O POINTS FOR E1 AND E2 BRAIN BOARDS

Module

position

on rack

Point

numbers

0 1

2 3

4 5

6 7

8 9

910

10 11

11 1 2

12 13

Module

position

on rack

Point

numbers

0 1

2 3

4 5

6 7

8 9

910

10 11

11 12

12 13

E1 shown with G4 modules

Points on G1s and integral racks are numbered the same.

E2 with G1 modules

Module

position

on rack

Point numbers

01234

1 5 6 7 8

2 9 10 11 12

3 13 14 15 16

E1 with Quad Pak modules

Quad Pak modules have four input or four output points.

REFERENCING I/O POINTS FOR E1 AND E2 BRAIN BOARDS

E1 brain boards can be used with a variety of digital module families; E2s are used with G1 analog modules only. However, the maximum number of points for either an E1 or an E2 brain board is 16 on the largest rack. When you use Modbus/TCP, point numbers are shown in the following examples. The largest rack is shown in each case.

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CONFIGURING I/O POINTS

To these registers:

Write this:

770

769

Before you can read or write to I/O points, you must configure point types and point features.

See instructions in form #1576, I/O Configuration for E1 and E2 Brain Boards.

Using Digital Point Features

For explanations of digital point features, see “E1 Brain Board Features” on page 5.

Latches

Latches are a digital point feature available on E1 brain boards. They do not require configuration. Read and clear latches as shown in the following table and the Modbus memory maps beginning on page 46:

To do this Use these addresses

Read the on-latch state Read inputs 65–80

Read the off-latch state Read inputs 129–144

Clear on-latches Write to coils 129–144

Clear off-latches Write to coils 193–208

Counters

CHAPTER 5: USING MODBUS/TCP

Using counters involves three steps: configure the counter (holding registers 769-800), activate the counter (coils 65-80), and read data (input registers 385-416). See “Modbus/TCP Memory Map for E1 and E2 Brain

Boards” on page 46 to find the addresses mentioned.

To do this Use these addresses

Write to holding registers 769–800. Remember that you use two consecutive registers for each point, since the data is in the form of a 32-bit integer but the registers are 16 bits each. For example, to configure point #1 as a counter, you would write 01 to regis-

Configure a counter

Activate a counter

Read counter data Read input registers 385–416. Read two consecutive registers per point.

Clear a counter

ters 769-770.

Write to coils 65-80. For example, to activate the counter for point #1, you would write to coil number 65.

Write to coils 257–272. For example, to clear the counter on point #1, you would write a 1 to coil 257.

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MODBUS/TCP MEMORY MAP FOR E1 AND E2 BRAIN BOARDS

Using Analog Point Features

For explanations of analog point features, see “E2 Brain Board Features” on page 6.

Analog point features generally require that you read or write two consecutive registers for each point, since the data is in the form of a 32-bit IEEE float. Data is in Big Endian format. You can change the word order if you wish, using Holding Register 1029, which is described in the table on page 48. If you change word order, be sure to store configuration information to flash (Holding Register 1026) so it will be saved when power to the brain board is cycled.

Scaling

You must scale analog points when you configure I/O. For instructions, see form #1576, I/O Configuration for E1 and E2 Brain Boards.

Maximum and Minimum Values (Peaks and Valleys)

Minimum and maximum values are analog point features. The brain board automatically keeps track of minimum and maximum values. For example, you can read the values at any time to record minimum and maximum pressures. You can also clear them.

NOTE: The E2 does not maintain minimum and maximum values for temperature.

• To read min/max values, read input registers 129–160 (min) and 257–288 (max). Read two consecutive addresses per point.

• To clear min/max values, write 1 bit to coils 321–336 (min) and 385–400 (max).

Offset and Gain

You can monitor current values for offset and gain using holding registers 129–160 and 257–288. To perform calibration on analog points, use PAC Manager. See form #1714, Legacy Edition PAC Manager User’s Guide.

MODBUS/TCP MEMORY MAP FOR E1 AND E2 BRAIN BOARDS

Coils

For digital I/O counter activation and clearing of latches, and analog minimum/maximum values: Each address contains the data for one point. Data is either 0 or 1.

Coil Numbers E1 E2 Action Notes

1–16 (available)

17–64 (unavailable)

65–80 (available)

81–128 (unavailable)

129–144 (available)

144–192 (unavailable)

193–208 (available)

208–256 (unavailable)

257–272 (available)

272–320 (unavailable)

321–336 (available)

336–384 (unavailable)

385–400 (available)

400–448 (unavailable)



Read or Write Digital Outputs

Activate Counters (digital modules)

Clear On-latch (digital modules)

Clear Off-latch (digital modules)

Clear Counters (digital modules)

Clear Analog Mini-



mum Values

Clear Analog Maxi-



mum Values

1 = On, 0 = Off

1 = On, 0 = Off. Configure as a point feature first. See “Counters” on page 45.

1 = clear latches; 0 = do nothing

1 = clear counters; 0 = do nothing

1 = clear minimum values; 0 = do nothing

1 = clear maximum values; 0 = do nothing

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CHAPTER 5: USING MODBUS/TCP

Inputs

Digital inputs, latch states, and counter states: Each address contains the data for one point. Data is either 0 or 1. Digital inputs are available only on an E1.

Input Numbers E1 E2 Action Notes

1–16 (available)

17–64 (unavailable)

65–80 (available)

81–128 (unavailable)

129–144 (available)

145–192 (unavailable)

193–208 (available)

209–256 (unavailable)



Read Digital Inputs 1 = On, 0 = Off

Read State of On-latches (digital modules)

Read State of Off-latches (digital modules)

Read Counter Active State (digital modules)

1 = On, 0 = Off

1 = Active, 0 = Inactive

Input Registers

Analog input values and digital counter values. Register data is in the form of 32-bit floats or 32-bit integers. Because Modbus registers contain only 16 bits, you must use two consecutive registers to read the data for one point, starting with an odd-numbered register. See the example on page 48.

1–32 (available)

33–128 (unavailable)

129–160 (available)

161–256 (unavailable)

257–288 (available)

289–384 (unavailable)

385–416 (available)

417–512 (unavailable)



Read Analog Values IEEE 32-bit float

Read Analog Minimum Values



(Inputs only)

Read Analog Maximum Values



(Inputs only)

Read Digital Counter Data (digital modules)

IEEE 32-bit float

32-bit integer

You can read a maximum of 125 registers in one command.

Holding Registers

Analog output values, point and feature configuration, and miscellaneous. Most of this data is also in the form of 32-bit integers or 32-bit floats. For these formats, you must use two consecutive registers to read or write the data for one point, starting with an odd-numbered register. See the example on page 48.

Holding Register

Numbers

1–32 (available)

33–128 (unavailable)

129–160 (available)

161–256 (unavailable)

257–288 (available)

289–384 (unavailable)

385–416 (available)

417–512 (unavailable)

513–544 (available)

545–640 (unavailable)

641–672 (available)

673–768 (unavailable)

E1 E2 Action Notes

Read or Write Analog Out-

 



puts (Engineering Units)



Analog Offset IEEE 32-bit float



Analog Gain IEEE 32-bit float



Set Point Low Scale Value IEEE 32-bit float



Set Point High Scale Value IEEE 32-bit float

Configure Points

IEEE 32-bit float

32-bit integer (For information on configuring points, see form #1576, I/O Config- uration for E1 and E2 Brain Boards.)

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MODBUS/TCP MEMORY MAP FOR E1 AND E2 BRAIN BOARDS

Holding Register

Numbers

769–800 (available)

801–896 (unavailable)

897–1024 Reserved Reserved

1025

1026

1027

1028

1029

1030

E1 E2 Action Notes



 



 



 

Configure counters on digital input modules



Set Degrees in F or C

Store Configuration to Flash

Reset Points to Default

Erase Configuration in Flash

Set 32-bit Float Format

Hardware Reset

32-bit integer (See page 45 for information on using counters.)

16-bit integer. 1 sets degrees in F; 0 sets degrees in C.

16-bit integer. Any non-zero value stores configuration to flash, so it is restored when the brain board is turned on. 0 = no action. Stores the contents of Status Write, Point Config, and IP Security Config. Also stores IP information, including IP address, subnet mask, gateway address, and DNS address.

16-bit integer. Any non-zero value resets the brain board to defaults as follows:

• Clears offsets and gains, counters, latches, and min/max data.

• Turns off digital outputs.

• Sets analog outputs to zero scale (0

counts).

• (1027 is equivalent to 1028 followed by

1030. See 1030 below.)

16-bit integer. Any non-zero value clears flash.

16-bit integer. 0 = Big Endian; 1 = Word-swapped Big Endian.

Using Modbus Command 06 (Preset Single Register), write any non-zero value to reset hardware, which is just like cycling power to the brain board. If point configuration information has not been stored to flash or flash has been cleared (1028), points are reset to defaults. Reading always returns 0.

You can read a maximum of 125 registers in one command.

Using Input and Holding Registers

An example may help clarify how to use input and holding registers. Holding registers 1–31 are used to read or write analog values for 16 possible points. The first point is located in the first two registers, 1 (the low register) and 2 (the high register).

To figure out the Modbus register numbers for a specific analog point, use the following formula:

Modbus low register number = (analog point number * 2) –1

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CHAPTER 5: USING MODBUS/TCP

Remember that modules on the rack start with position 0, but that I/O points for Modbus start with point 1. For example, to read point #1 (position 0) and point #9 (position 8):

For point #1: (1 x 2) –1 = 1 for low register

=2 for high register

For point #9: (9 x 2) –1 = 17 for low register

= 18 for high register

Since the first register is odd-numbered, a read should always begin with an odd-numbered register. You can read a maximum of 125 registers in one command.

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MODBUS/TCP MEMORY MAP FOR E1 AND E2 BRAIN BOARDS

E1 and E2 User’s Guide

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Chapter 6

6: Troubleshooting

If you are having difficulty using an E1 or E2 brain board, here are some suggestions that might help. If you cannot find the answers you need in this book, contact Opto 22 Product Support. Contact information is on

page 4.

This chapter includes the following topics:

Troubleshooting Ethernet Communications below

Troubleshooting Serial Communications page 54

General Troubleshooting page 57

TROUBLESHOOTING ETHERNET COMMUNICATIONS

If you attempt to connect to the brain board using its IP address and you cannot, first check the following:

• Make sure the brain board has been turned on and the Status LED is on. (See “LED Descriptions” on

page 10.)

• Make sure the brain board is firmly attached to the rack.

• Verify that you typed in the correct address for the brain board. Check the small white area next to the

Ethernet port on the brain board, where the IP address should be written.

• Make sure the brain board has been assigned a valid IP address and subnet mask. E1 and E2 brain boards come from the factory with a default IP address of 0.0.0.0, which is invalid. The default subnet mask is

255.255.255.0. To assign the IP address and subnet mask, see form #1714, the Legacy Edition PAC Manager User’s Guide.

• If you are communicating only on an Ethernet network (no serial connections), make sure that only jumpers A1-A4 and A10 are installed on the brain. If any other jumper configuration is used, the RS-485 communication lines may cause interference. See page 21 for more information.

• Make sure you have up-to-date drivers installed on your computer’s Network Interface Card (NIC). Contact your system administrator or the manufacturer of the card for help.

• Make sure you have Administrator privileges on your computer and that any firewall in the computer (such as the built-in firewall in Windows XP) is temporarily disabled before you try to assign or change IP addresses, load firmware using PAC Manager’s Maintenance window, or FTP files to the brain board. DHCP and FTP cannot function through a firewall in the PC. Firewalls in a router are less likely to be a problem unless certain ports (such as FTP client) have been blocked, either by default or on purpose.

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TROUBLESHOOTING ETHERNET COMMUNICATIONS

Pinging the Brain Board

If you still cannot communicate with the brain board after you have checked these items, try to reach it using the PING protocol.

1. Open an MS-DOS command prompt window.

2. At the prompt, type:

For example, type: ping 10.192.54.40

If the brain board responds, go to “Accessing the Brain Board with PAC Manager” on page 52.

If the PING command cannot be found, choose Start > Control Panel > Network. Make sure TCP/IP is

configured as a protocol and that an IP address and subnet mask are assigned.

If you see the message “Destination host route not defined,” the brain board probably has an inappropriate IP address and subnet mask. Make sure the IP address and subnet mask on the brain board are compatible with those on the computer. Follow the directions beginning on page 35 to check the IP address and subnet mask on the brain board, and change them if necessary.

If you see the message “No response from host,” check the following:

• Are the computer and brain board correctly connected? Is the brain board turned on?

• Are the IP address and subnet mask on the brain board compatible with those on the computer?

• Is the brain board in reset mode? (Check for a blinking STAT LED. STAT LED blink codes are shown on

page 10.)

ping [brain board’s IP address]

If you still cannot ping the brain board, contact Opto 22 Product Support. (See page 4.)

Accessing the Brain Board with PAC Manager

Once you know you can ping the brain board, try to access it using PAC Manager. You will need to know the brain board’s IP address.

1. If PAC Manager is not already open, choose Start > Programs > Opto 22 > PAC Manager. The PAC Manager main window opens:

2. In the PAC Manager main window, click the Inspect button .

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CHAPTER 6: TROUBLESHOOTING

Date and time data was last read

Click to update data

3. In the IP Address field, type the IP address of the brain board (or choose it from the drop-down list).

4. Click Status Read.

Information from the brain board is displayed in the window:

If information does not appear and an error is indicated in the Status field, contact Product Support. (See

page 4.)

Solving Network Problems

If problems in communicating with the E1 and E2 recur, check your network. The wires, switches, and so on in your Ethernet network are not part of the Opto 22 hardware, but any problems in your network may affect communication with Opto 22 products.

Create a Network Diagram

First, create a network diagram and verify the following:

• Cable connectors are firmly inserted.

• The switch has power. Switch LEDs indicate that the connection is up.

• Neither the PC nor the I/O unit uses the switch’s uplink port.

• The brain board’s Link LED is lit.

Analyze Communication Packets

If it appears that you have network problems, you can use a network sniffer utility, such as Wireshark (http://www.wireshark.org/) to log and analyze network communication packets.

Have Your Network Certified

If you suspect network problems, you may need to have your network professionally certified. Opto 22 does not offer network validation or certification services, but many network hardware manufacturers do. Contact the manufacturer of your Ethernet network hardware to have them diagnose, fix, and certify your network.

If you continue to have problems communicating with the E1 and E2after your network is certified, contact Opto 22 Product Support. (See page 4.)

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TROUBLESHOOTING SERIAL COMMUNICATIONS

Solving Common Communications Errors

Use this section to diagnose the most common causes of communication problems:

• 5 VDC power adjusted too low at brain boards

• Incorrect jumper settings

• Wiring problems

For error codes that might appear when using Optomux, see page 56.

Power Tips

1. Ensure that the 5 VDC power supply wiring connections are secure.

2. Ensure that the voltage is 5.1-5.2 VDC as measured on the brain board. Check voltage at all the Optomux

brain boards by measuring across a capacitor on the brain board itself, not across the power supply terminals. For more information, see form #1271, Using Power Supplies.

3. Ensure that the power supply has no ripple. If possible, inspect the power supply voltage with an oscilloscope, instead of using only a multimeter. Multimeters sometimes do not catch fast AC signals and transients.

4. Make certain that the power supplies are floating; that is, do not connect the power supply common (5 VDC return) to chassis/earth ground.

5. Make sure that the 5 VDC power supply common is not connected to the +/- 15 VDC common terminal on analog mounting racks; this can cause unstable analog readings.

Jumper Tips

For an easy way to see which jumpers to set, go to our website and use the E1/B1 Brain Jumper Configurator or the E2/B2 Brain Jumper Configurator.

If you need to know how a brain board is currently configured, use these interactive demos: Read E1/B1

Jumper Settings or Read E2/B2 Jumper Settings.

1. Make sure the jumpers are intact. The red jumpers provided with Optomux brain boards consist of a metal jumper on the inside covered by red plastic. Sometimes the metal portion of the jumper separates from the red plastic piece, causing incorrect jumper settings even though the jumpers seem to look correct.

For example, if a jumper is removed but the internal metal pieces stay attached to the brain board, the jumper will look like it is removed, but the brain will detect that it is installed.

On the other hand, the jumper can appear to be installed when it is not. This happens when the red plastic part is installed but is missing the metal internal piece. In this case, the brain board will detect that the jumper is removed.

2. Make certain that the addresses are set correctly. No two brain boards on the same network can have the same address. If two or more brains on the same network have the same address, they will respond at the same time, causing a garbled response received at the host.

3. Make certain that the baud rates are set correctly. The host device and all brain boards must be operating at the same baud rate. A brain board set for the wrong baud rate will not respond.

4. Make certain the last Optomux brain board on the communications link has the correct termination jumpers installed (jumpers A0 and A6 for brains set up in multi-drop mode).

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CHAPTER 6: TROUBLESHOOTING

5. Make sure the host RS-422/485 device is configured to provide the correct termination and biasing.

– The host receive pair (FO) must provide both termination and biasing, because this part of the link is

RS-485.

– The host transmit pair (TO) must provide for termination and possibly biasing, depending on the

interface device. Check the following to make sure it is set up correctly: – The RS-422 transmit pair must provide end-of-line termination resistor. – If the transmitter is actually an RS-485 transmitter, then biasing resistors are also necessary.

NOTE: An RS-485 transmitter will be disabled (tri-stated) when not transmitting, so the transmit pair will “float” and might allow fluctuations to be interpreted as data or errors. However, an RS-422 transmitter will remain enabled in either high or low state when not actively transmitting data, so it is not possible for fluctuations, and thus, biasing is not needed.

NOTE: Some non-Opto 22 RS-422/485 interface products do not provide an option for termination and/or biasing. If the interface product does not provide the necessary options, then it will have to be replaced with one that does. Termination resistors can be applied externally, but biasing resistors typically cannot.

Communication Wiring Tips

1. Make sure to use a shielded, twisted-pair RS-422/485 communication cable with at least three twisted

pairs as detailed below. If you use a cable with four twisted pairs, you will have one extra pair. – Two pairs for data (a transmit pair and a receive pair), and – One pair to use for the signal common

– The signal common requires only one insulated conductor, but it is hard to find a cable with

two pairs plus an extra insulated wire that is separate from the shield drain wire.

– For the signal common, you can use both wires from the pair tied together or just one of the

wires.

2. Ensure that the signal common is connected from one brain board to the next and also to the host

RS-422/485 device. This must be done with an insulated wire, which is typically one wire in the overall communication cable.

3. Make sure that the COM terminal (signal common) on the brain boards is not connected to chassis/earth

ground.

4. Ensure that the overall cable shield drain wire is connected to chassis/earth ground at one location only.

Do not connect the shield drain wire to the COM (signal common) terminal on any brain board.

5. Make sure the communications cable is daisy-chained from brain to brain; no “Ts” are allowed under the

RS-422/485 specification.

6. Make sure the communications pairs are not crossed. In some types of cable, one wire from each pair is

the same color. This makes it very easy to get those wires mixed up. If you strip back the jacket and shield far enough, it will become clear which wire belongs to which pair.

7. Check the polarity of the + and – communication wires throughout each twisted pair. If you have one or

more receive LEDs stuck on, this may be the cause. Incorrect biasing might also cause this.

8. Power down each brain board in the link, and check the resistance of each twisted pair. One basic check

of the communication wiring in a multidrop system is to measure the resistance across the + and – lines of each twisted pair. There should be a 220 ohm resistor across the + and – wires of each data pair (transmit and receive) at each end of the cable. If both ends are terminated properly, you should see about 110 ohms, because there should be termination (220 ohms) at both ends. Make certain that in a multidrop system, only the last physical brain board on the communication link has jumpers A0 and A6 installed.

9. If using an RS-232 to RS-422/485 converter at the host end of the system, make sure that CTS

handshaking is disabled on the host. Otherwise, jumper RTS to CTS at the host end. If RTS/CTS handshaking is enabled (and not jumpered), the host will not transmit; no data will be allowed to go out the computer's RS-232 com port.

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TROUBLESHOOTING SERIAL COMMUNICATIONS

Other Tips:

1. Diagnostic/Test Utilities: Test the system using one of the Optomux utilities, such as OptoScan, which can trap errors. Often, the errors received can help determine the nature of the problem. If OptoScan works properly and there are no errors, the cause of the problem might be the host software.

2. Baud Rate: Try running the system at a lower baud rate. Lower baud rates are more forgiving in a noisy environment.

3. LED Indicators: If you see receive LEDs blinking on the brain boards, but not transmit LEDs, the cause of the problem could be incorrect address or baud rate settings on one or more brain boards. It can also be caused by wiring problems, low voltage, or noisy power.

4. Computer Issues: If you are using an ISA bus RS-422/485 card in the host computer, make sure that there are no I/O port or IRQ conflicts.

5. Loopback test: If the host device is a PC, it is possible to verify the operation of the RS-422/485 port by jumping TX+ to RX+, and TX- to RX- (these are TO and FO on Opto 22 brain boards) at the computer. A communication program such as Windows Terminal or Hyperterminal can be used to test the communications with the port.

Make sure the terminal test utility is set up with flow control set to None and that the local echo is turned off. Once started, anything typed on the keyboard should be displayed on the screen. If this does not happen, there may be a hardware or configuration problem with the communication port. Also remember that Opto 22 ISA bus serial adapter cards do not use standard Windows COM port settings (I/O port base address and IRQ) for COM3 and COM4. Make sure that the host software is using the correct I/O port base address and IRQ.

6. Call Opto 22 Product Support. Contact information is on page 4.

Error Codes When Using Opto 22 Optomux Driver

This is a list of the most common driver error codes relating to problems with the RS-422/485 network or brain boards. For a complete list, see form #1572, the Optomux Protocol Guide.

Errors Returned by the Brain Board

The following error conditions are caught by (generated by) the brain board.

–1 Power Up Clear Expected.

Command Ignored. A command other than “A” (Power-Up Clear) was attempted after power-up or power failure. Once the error is received, it is not necessary to execute a Power-Up Clear command. The next command will be executed normally. IMPORTANT: If this error message is received, it means that the Optomux unit has gone through its power-up sequence and has reset all characteristics to defaults. The unit needs to be reinitialized.

The brain contains a voltage watchdog circuit. If the 5 VDC logic supply voltage falls below the reset voltage, the brain will automatically reset. Use a high-quality DVM (Digital Volt Memory) or a high-precision oscilloscope to examine the brain's supply voltage. Power supply selection or design, poor power distribution techniques, or loose power wiring may cause spurious power-up-clear alerts. For more information, see form #1271, Using Power Supplies.

–3 Checksum Error.

This error indicates that the checksum received by the brain board did not match the checksum calculated by the brain board. The command message was corrupted while being transferred over the wire. Data corruption can occur due to improper wiring, termination, and/or radio frequency or electromagnetic noise.

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–5 The brain received a non-printable ASCII character.

Only characters from 21 Hex to 7F Hex are permitted within Optomux messages. This error is most likely caused by some kind of data corruption. The command is ignored. Data corruptions may occur due to improper wiring, termination, and/or spurious radio frequency or electromagnetic noise.

Driver Errors

These are error conditions caught by (generated by) the driver.

–29 Turnaround Time Out.

The brain board did not respond within the specified time interval or did not respond at all. Timeouts occur if the timeout interval is too short or the brain board is not available. Possible causes of a brain board not being available include power/voltage problems, the brain board's jumper settings being incorrect (address, baud rate, 2/4 pass mode, termination, etc.), or there is a problem with the communication wiring.

–31 Checksum Error.

The checksum of the message received by the Optomux driver does not match the checksum calculated by the driver. Data corruption can occur due to improper wiring, termination, and/or radio frequency or electromagnetic noise.

–33 Send Error.

This error indicates that the Optomux driver cannot send the message. The most likely cause is a problem with the serial port being in use by another application.

–34 Incorrect Command Echo In Four-Pass.

The command echo does not match the command sent. The addressed brain board is probably in the two-pass mode. This error can occur only when the driver is configured for 4-pass mode. 4-pass mode was originally intended for diagnostic purposes, but it is generally not used even for that purpose. It is best to always use 2-pass mode.

Other Error Codes

These are error codes returned from brain when not using Opto 22 driver:

00 Powerup Clear Expected - Command Ignored . See “–1 Power Up Clear Expected” on page 56.

02 Checksum Error. See “–3 Checksum Error” on page 56.

GENERAL TROUBLESHOOTING

I send a command to activate several outputs. The brain board responds with no error, but none of my outputs comes on.

If an output point does not turn on, check the following:

• Make sure you configured the output points correctly. On power-up, the unit defaults to all points

configured as inputs.

• If power went out and came back on, the unit will have lost its configuration.

• Make sure you are using output modules with a 5 VDC logic voltage (OAC5, ODC5, etc.). Sometimes

modules with a 15 VDC or 24 VDC logic voltage (ODC15, OAC24, etc.) are used by mistake. The LED may turn on or be dim with the 15 VDC and 24 VDC modules, but there will be no output on the field side.

• If the output LED is on, but the load does not turn on, check the field voltage, wiring, and fuse. This could

result in a field device not turning on.

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GENERAL TROUBLESHOOTING

I send a command to turn on output point 5 of a digital brain board and output point 4 goes on.

Points are numbered from 0 to 15; therefore the fifth bit in the bitmask is for point 4. Following are the bitmask values for each point, in hex:

Point Bitmask (Hex) Point Bitmask (Hex)

0 0001 8 0100

1 0002 9 0200

2 0004 10 0400

3 0008 11 0800

4 0010 12 1000

5 0020 13 2000

6 0040 14 4000

7 0080 15 8000

I’m using OptoMMP, and the counts returned are very different from what I expect.

Check the configuration on your E2. The OptoMMP protocol returns counts differently, based on how the E2 was configured. (See “E2 Brain Board Features” on page 6.)

• Modules configured directly as G1 modules (new method; requires E2 firmware R1.2a or higher and PAC Project 9.5 or higher) will report counts as G1 counts (0–4095 nominal range).

• Modules configured as similar SNAP modules (old method using form 1576) will report counts as 0– 25000 or -25000 to +25000.

When I read point 3 on an E2 Optomux unit via the Optomux protocol, I receive 0000 hex, which converts to a decimal -4096 value when I subtract the 1000 hex offset.

A -4096 decimal reading may indicate one of the following:

• You are reading a point where no input module is installed.

• You are reading a point on a thermocouple module that has no thermocouple installed, or the

thermocouple probe is open.

• An ICTD module has the ICTD wired in reverse.

• A 4–20 mA module is wired with reverse polarity.

• The field connections are made to the wrong terminals. Field connections vary with each module. Refer

to the module data sheet for information on wiring each module. In general, field connections made to the terminals on the rack are made to the terminals labeled UPPER (closest to module), and if the module has terminals on the top of the module, connections would be made there. Analog racks have the module positions labeled from 1 to 16. These points correspond to module positions 0 to 15, respectively.

• If all inputs on that brain board have the same -4096 reading, then check to make sure the unit has +15 and -15 VDC at the corresponding terminals (with reference to the terminal that is marked COMMON).

Does Opto 22 have any troubleshooting software for the Optomux system?

Yes. Opto 22 has the OptoScan (oswin32.exe) and OmuxUser (omuxuser.exe) utilities that can be used to troubleshoot an Optomux system attached to a PC. These are Visual Basic 6 applications and are included with the Optomux Protocol Drivers and Utilities download. Source code is included as an example of Opto 22’s Optomux driver DLLs. These applications include the ability to manually configure and poll a digital or analog brain board. The toolkit is available on Opto 22’s website, www.opto22.com. For MS-DOS and Windows for Workgroup (WFWG) versions of OptoScan, contact Opto 22 Product Support.

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CHAPTER 6: TROUBLESHOOTING

Serial Communications Questions and Answers

I send a command message to a brain board, and I get no response. However, the unit’s LED flashes.

The receive LEDs on all the brain boards wired in a multidrop mode should blink whenever a command is sent from the host. Only the unit at the address that matches the command message address should respond. When a brain board responds, the XMT (transmit) LED blinks. At high baud rates, and for messages with only a short response, the blink will be so brief that it may be missed visually.

If the host receives no response, and no blink of the XMT light is visible (even at slower baud rates), then check the following:

• Make sure the address in the command message matches the unit’s address. Check the jumpers. A

common mistake is a reversal of jumpers. All address jumpers (B0 through B7) installed corresponds to address 0, and all address jumpers (B0 through B7) removed corresponds to address 255. See “Setting

Jumpers (Serial Only)” on page 17.

• Make sure the baud rate is correct between the host and the unit. All brain boards on the same link

should be configured to the same baud rate.

• Make sure you have a solid 5.1–5.2 VDC (as measured on the brain) powering the brain board. If the

voltage is too low, the RCV light may flash, but the unit will not be able to respond. Measure the voltage across one of the yellow capacitors on the brain board. See form #1271, Using Power Supplies.

• Check to make sure the communications link is wired with the correct polarity and that jumper group A is

configured correctly.

I receive a large number of checksum errors when I send commands to Optomux brains.

Make sure that you are using twisted pair cable. See the cables recommended on page 22. The RS-422/485 network is reliable only when the communications cable is twisted pair (+ and – lines of EACH pair twisted together). If there are two or more wires in the cable with the same color (such as a red/black pair, a white/black pair), sometimes the same-colored wires may be associated with the wrong mates. To make sure the wiring is correct, strip the jacket back far enough to properly identify the individual pairs.

Also check the Group A jumpers to make sure the termination jumpers are configured correctly.

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GENERAL TROUBLESHOOTING

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Appendix A

A: Serial-to-Ethernet Routing

If you need to keep existing serial-based host Optomux software, you can extend your system beyond the physical limitations of an RS-422/485 link by using an E1 or E2 to route control coming through a serial network to remote locations over Ethernet.

To do so, replace existing B1s and B2s with E1s and E2s, keeping the same racks and I/O. Keep the serial link from the host to the first E1’s or E2’s serial port, and put all the E1s and E2s on an Ethernet network. With an Ethernet network, the I/O units can be literally anywhere in the world.

This scenario is shown in the diagram on the following page.

Your existing Optomux application continues to run over serial without needing any changes; the first E1 or E2 translates communications between the host and all other I/O units. You can acquire data over Ethernet via OPC or Modbus/TCP at the same time.

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This figure shows an E1 used as a serial-toEthernet router.

The host communicates to the first E1 or E2 over serial, using Optomux. The first brain routes communication to other E1 and E2 I/O units on the Ethernet network.

In this scenario, existing software running on the host does not have to be changed.

Ethernet network

E1 configured for serial-to-Ethernet routing

Host using Optomux over serial (RS-422/485) link

Serial-to-Ethernet Routing uses a routing table that resides on the first E1 or E2, in which each entry associates an Optomux address with an Ethernet host name or IP address, a protocol (currently UDP only), and a port. When an Optomux packet is received from the serial port, the brain board compares the Optomux address in the packet to the Optomux addresses in the routing table. If there’s a match, the packet is forwarded to the appropriate device (including itself) via UDP/IP.

When the response is received via UDP, it is forwarded to the serial network. The maximum number of Optomux devices that can be accessed through serial-to-Ethernet routing is 256, because an Optomux host can communicate with no more than 256 devices. The E1 or E2 doing serial-to-Ethernet routing also behaves as an Optomux device on the RS-422/485 link.

To use serial-to-Ethernet routing, you need to follow the steps below to create the OmuxRoutes routing table and then enable serial-to-Ethernet routing in the OmuxSettings file.

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CREATING A ROUTING TABLE

The routing table is a text file that you can create or edit in Notepad and then transfer to the E1 or E2 using PAC Manager. The OmuxRoutes table should reside only on the first E1 or E2.

NOTE: PAC Manager uses FTP to transfer files. FTP cannot be used through a firewall in the PC. Make sure any firewall in the computer (such as the built-in firewall in Windows XP) is disabled before you try to transfer the file to the brain board. (Firewalls in a router should not be a problem.)

1. Open Notepad or any simple text tool and create a new file.

2. In the file, type one line for each Optomux address, in the following format:

[Optomux_address] [type]:[host name or IP address]:[port]

The space between [Optomux address] and [type] can be one or more spaces. The value for [type] is currently is already being used for another purpose.) Each entry must end with a carriage return.

For example:

42 udp:valve_control:5000

112 udp:10.192.55.61:5000

Alternatively, you can use commas as follows:

42,udp,valve_control,5000

112,udp,10.192.55.61,5000

A sample routing table is shown on page 64.

3. Save the file with the filename

udp. The default value for [port] is 5000. (Change it only if port 5000 on the Ethernet network

APPENDIX A: SERIAL-TO-ETHERNET ROUTING

OmuxRoutes

NOTE: An example of an OmuxRoutes file is provided in the software available on the Opto 22 website.

4. If PAC Manager is not already open, choose Start > Programs > Opto 22 > PAC Manager.

5. In the PAC Manager main window, click the Maintenance button .

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ENABLING SERIAL-TO-ETHERNET ROUTING

# Routing Entries for the system. # Note that port 5000 is the default # E1 UDP port.

4 udp:10.0.0.8:5000 # comment 5 udp:10.0.0.9:5000 6 udp:10.0.0.10:5000

# The following entry uses hostname instead of IP # address.

55 udp:my_e1_hostname:5000

6. In the I/O Unit Maintenance window, do the following to copy the OmuxRoutes file to the first E1 or E2:

a. In the Command list, choose Upload File To I/O Unit. b. In the Filename field, click the browse button . c. In the Open dialog, browse to the OmuxRoutes file, and double-click it to open it.

The path and filename appear in the Filename field.

d. In the Destination field, type the name OmuxRoutes. e. If the IP Address for the E1 or E2 is listed under IP Addresses, go to the next step. If the IP address is

not in the list, click the Add button and add it.

f. Highlight the IP address, and click Execute.

The updated OmuxRoutes file is copied to the E1 or E2, and the new settings take effect right away.

7. Continue with “Enabling Serial-to-Ethernet Routing,” below, to change the OmuxSettings file.

Sample Routing Table

Following is a sample OmuxRoutes file. (Text after a # on any line is a comment.)

ENABLING SERIAL-TO-ETHERNET ROUTING

1. If PAC Manager is not already open, choose Start > Programs > Opto 22 > PAC Manager.

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APPENDIX A: SERIAL-TO-ETHERNET ROUTING

2. In the PAC Manager main window, click the Maintenance button .

3. In the I/O Unit Maintenance window, do the following to copy the OmuxSettings file to your computer:

a. In the Command list, choose Download File From I/O Unit. b. In the Filename field, type OmuxSettings. c. In the Destination field, click the browse button .

The Save As window opens.

d. Browse to a convenient directory on the computer. Type OmuxSettings and click Save.

The path and filename appear in the Destination field.

e. Click the Add button.

The Add IP Address window opens.

f. Enter the IP address of the E1 or E2 and click Save.

The IP address appears in the IP Addresses list.

g. Select the appropriate IP address, then click the Execute button.

The OmuxSettings file is copied to your computer.

4. Open the OmuxSettings file in Notepad or another simple text tool.

NOTE: An example of an OmuxSettings file is included in the software available on the Opto 22 website.

5. Add the text SerialToEthernetRouting

6. Save the file as OmuxSettings

7. In PAC Manager’s I/O Unit Maintenance window, do the following to copy the OmuxSettings file to the E1

or E2:

a. In the Command list,

choose Upload File To I/O Unit.

b. In the Filename field, click the browse button .

The Open File dialog opens.

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DISABLING SERIAL-TO-ETHERNET ROUTING

c. Browse to the OmuxSettings file, then click Open.

The path and filename appear in the Filename field.

d. In the Destination field, type the name OmuxSettings e. If the IP Address for the E1 or E2 is listed under IP Addresses, go to the next step. If the IP address is

not in the list, click the Add button and add it.

f. Highlight the IP address, and click Execute.

The updated OmuxRoutes file is copied to the E1 or E2, and the new settings take effect right away.

DISABLING SERIAL-TO-ETHERNET ROUTING

To stop serial-to-Ethernet routing:

1. Open the OmuxSettings file.

2. Remove the text:

3. Save the file.

4. Send the OmuxSettings file to the E1 or E2. See “Enabling Serial-to-Ethernet Routing” on page 64.

SerialToEthernetRouting

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Appendix B

B: Using the OmuxSettings File

ABOUT THE OMUXSETTINGS FILE

In addition to jumper settings, E1 and E2 brain boards are configured in the OmuxSettings file, a text file located on the E1 and E2. This file determines whether the E1 and E2 listen on the serial link or the Ethernet link (or both), whether Serial-to-Ethernet routing is enabled, and what happens to troubleshooting log files. The brain board will function using the default settings unless you change them as described below.

The default settings for the OmuxSettings file are as follows:

Setting Default Description

EthernetPort 5000

EthernetServer enabled

SerialServer enabled

SerialToEthernetRouting disabled

The UDP port number the E1 or E2 responds to for communications.

Listens for Optomux commands (UDP) on the UDP port specified by EthernetPort.

Listens for Optomux commands on the Serial port.

When enabled, E1 or E2 can serve as a serial-to-Ethernet router. See Appendix A:

Serial-to-Ethernet Routing.

CHANGING THE OMUXSETTINGS FILE

NOTE: PAC Manager uses FTP to transfer files. FTP cannot be used through a firewall in the PC. Make sure any firewall in the computer (such as the built-in firewall in Windows) is disabled before you try to transfer the changed OmuxSettings file to the brain board. (Firewalls in a router should not be a problem.)

1. If PAC Manager is not already open, choose Start > Programs > Opto 22 > PAC Manager.

The PAC Manager main window opens:

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CHANGING THE OMUXSETTINGS FILE

2. In the PAC Manager main window, click the Maintenance button . The I/O Unit Maintenance window opens:

3. In the I/O Unit Maintenance window, do the following to copy the OmuxSettings file to your computer:

a. In the Command list, choose Download File From I/O Unit. b. In the Filename field, type OmuxSettings c. In the Destination field, click the browse button .

The Save As window opens.

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APPENDIX B: USING THE OMUXSETTINGS FILE

d. Browse to a directory on the computer, type OmuxSettings and click Save.

The path and filename appear in the Destination field.

e. Click the Add button.

The Add IP Address window opens.

f. Enter the IP address of the E1 or E2, and click Save.

The IP address appears in the IP Addresses list.

g. Select the appropriate IP address, then click the Execute button.

The OmuxSettings file is copied to your computer.

NOTE: An example of an OmuxSettings file is included in the software available on the Opto 22 website.

4. Open the OmuxSettings file in Notepad or another simple text tool.

5. Add, change, or delete the following communication items, depending on your needs:

To do this Add/change/delete this text

Change the Ethernet port number Add: EthernetPort=[port number]

Listen on the Ethernet link Add: EthernetServer

Stop listening on the serial link Delete: SerialServer

Enable Serial To Ethernet Routing Add: SerialToEthernetRouting

6. Save the file as

OmuxSettings

7. In PAC Manager I/O Unit Maintenance window, do the following to copy the OmuxSettings file to the E1

or E2:

a. In the Command list, choose Upload File To I/O Unit. b. In the Filename field, click the browse button. c. In the Open dialog, browse to the OmuxSettings file, then click Open.

The path and filename appear in the Filename field.

d. In the Destination field, type the filename OmuxSettings. e. If the IP Address for the E1 or E2 is listed under IP Addresses, go to the next step. If the IP address is

not in the list, click the Add button and add it.

f. Highlight the IP address, and click Execute.

The updated OmuxSettings file is copied to the E1 or E2, and the new settings take effect.

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CHANGING THE OMUXSETTINGS FILE

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Appendix C

C: Licensing Information

SOFTWARE LICENSES USED IN E1 AND E2 BRAIN BOARDS

Some software used by Opto 22 E1 and E2 brain boards is subject to various software licenses. This appendix explains software licensing in more detail.

Opto 22 License Agreement for Embedded Software

This product contains copyrighted Opto 22 software covered by the Opto 22 License Agreement for Embedded Software. This software uses the uClibc library. The uClibc library is subject to the GNU Lesser General Public License.

Please see “Opto 22 License Agreement for Embedded Software” on page 73 for the exact terms and conditions of the Opto 22 License Agreement for Embedded Software.

Please see “GNU Lesser General Public License” on page 78 for the exact terms and conditions of the GNU Lesser General Public License.

GNU General Public License

This product includes copyrighted third-party software licensed under the terms of the GNU General Public License.

Please see “GNU General Public License” on page 74 for the exact terms and conditions of the GNU General Public License.

Please see the Open Source Software distribution for this product, available at www.opto22.com, for a list of the parts of this product subject to GNU General Public License.

All third-party software packages are copyrighted by their respective authors. Please see the source code for detailed information.

Full source code of the GPL licensed software, including any scripts to control compilation and installation of the object code, is available in the Open Source Software distribution for this product at www.opto22.com.

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SOFTWARE LICENSES USED IN E1 AND E2 BRAIN BOARDS

GNU Lesser General Public License

This product includes copyrighted third-party software licensed under the terms of the GNU Lesser General Public License.

Please see “GNU Lesser General Public License” on page 78 for the exact terms and conditions of the GNU Lesser General Public License.

Please see the Open Source Software distribution for this product, available at www.opto22.com, for a list of the parts of this product subject to GNU Lesser General Public License.

All third-party software packages are copyrighted by their respective authors. Please see the source code for detailed information.

Full source code of the LGPL licensed software, including any scripts to control compilation and installation of the object code is available in the Open Source Software distribution for this product at www.opto22.com.

Berkeley Software Distribution License

This product includes copyrighted third-party software licensed under the terms of the Berkeley Software Distribution License:

This code is derived from software written by Ken Arnold and published in UNIX Review, Vol. 6, No. 8.

Redistribution and use in source and binary forms, with or without modification, are permitted provided that the following conditions are met:

1. Redistributions of source code must retain the above copyright notice, this list of conditions and the

following disclaimer.

2. Redistributions in binary form must reproduce the above copyright notice, this list of conditions and the

following disclaimer in the documentation and/or other materials provided with the distribution.

3. All advertising materials mentioning features or use of this software must display the following

acknowledgement:

This product includes software developed by the University of California, Berkeley and its contributors.

4. Neither the name of the University nor the names of its contributors may be used to endorse or promote

products derived from this software without specific prior written permission.

THIS SOFTWARE IS PROVIDED BY THE REGENTS AND CONTRIBUTORS “AS IS'' AND ANY EXPRESS OR IMPLIED WARRANTIES, INCLUDING, BUT NOT LIMITED TO, THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE ARE DISCLAIMED. IN NO EVENT SHALL THE REGENTS OR CONTRIBUTORS BE LIABLE FOR ANY DIRECT, INDIRECT, INCIDENTAL, SPECIAL, EXEMPLARY, OR CONSEQUENTIAL DAMAGES (INCLUDING, BUT NOT LIMITED TO, PROCUREMENT OF SUBSTITUTE GOODS OR SERVICES; LOSS OF USE, DATA, OR PROFITS; OR BUSINESS INTERRUPTION) HOWEVER CAUSED AND ON ANY THEORY OF LIABILITY, WHETHER IN CONTRACT, STRICT LIABILITY, OR TORT (INCLUDING NEGLIGENCE OR OTHERWISE) ARISING IN ANY WAY OUT OF THE USE OF THIS SOFTWARE, EVEN IF ADVISED OF THE POSSIBILITY OF SUCH DAMAGE.

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APPENDIX C: LICENSING INFORMATION

OPTO 22 LICENSE AGREEMENT FOR EMBEDDED SOFTWARE

NOTICE TO USER: THIS IS A CONTRACT. CAREFULLY READ THIS AGREEMENT BEFORE USING THE DEVICE IN WHICH THE SOFTWARE IS INCORPORATED. BY USING THE DEVICE, YOU ACCEPT ALL THE TERMS AND CONDITIONS OF THIS AGREEMENT. IF YOU DO NOT AGREE TO THESE TERMS, DO NOT USE THE DEVICE. YOU MAY, WITHIN FIFTEEN (15) DAYS OF PURCHASE, REQUEST A FULL REFUND.

GRANT. You have acquired a device (“Device”) that includes software components created and copyrighted by Opto 22, Inc. (“Opto 22”). The installed software of Opto 22 origin (“Software”) is protected by international intellectual property laws treaties, as well as other intellectual property laws and treaties. The Software is licensed, not sold.

Opto 22 hereby grants to you a non-exclusive license to: (i) use the Software on the Device in which it is incorporated; (ii) transfer the Software to a recipient on a permanent basis provided the recipient agrees to the terms and conditions of this Agreement.

You may not: (i) modify, translate, reverse engineer, decompile, or disassemble (except to the extent applicable laws specifically prohibit such restrictions, and as expressly set forth in the section “OPEN SOURCE SOFTWARE”) or create derivative works based on the Software, or any portion thereof; (ii) copy the Software (except for backup purposes); or (iii) use Opto 22’s or Opto 22’s suppliers’ name, logos, or trademarks in any manner including, without limitation, in your advertising or marketing materials, except as is necessary to affix the appropriate copyright notices as required herein.

OPEN SOURCE SOFTWARE. The Software uses other software components that are subject to the GNU Lesser General Public License (“LGPL”). In compliance with the terms of the LGPL, Opto 22 makes its modifications to LGPL software that Opto 22 uses, modifies and distributes pursuant to the LGPL available in source code form to the public at www.opto22.com. You are free to use, modify and distribute software that is subject to the LGPL as long as you comply with the terms of the LGPL (available in the product manual or at www.gnu.org/copyleft/lgpl.html).

In compliance with the terms of the LGPL, Opto 22 makes its Software that dynamically links to LGPL software available as an executable file. You may modify the executable file for your own use, and reverse engineer the executable file for debugging such modifications.

TITLE. Title, ownership rights, and intellectual property rights in and to the Software shall remain in Opto 22 and/or its suppliers. The Software is protected by the copyright laws of the United States and international copyright treaties. Title, ownership rights, and intellectual property rights in and to the content accessed through the Software is the property of the applicable content owner and may be protected by applicable copyright or other law. This License gives you no rights to such content.

LIMITED WARRANTY. Opto 22 warrants that: (i) the Software will substantially conform to the accompanying documentation. Opto 22’s sole liability, and your sole remedy, for any breach of this warranty shall be, in Opto 22’s sole discretion: (i) to replace your non-conforming Software; or (ii) if the above remedy is impracticable, to refund the license fee you paid for the Software. Replaced Software shall be covered by this limited warranty for the period remaining under the warranty that covered the original Software, or if longer, for thirty (30) days after the date of shipment to you of the replaced Software. Only if you inform Opto 22 of your problem with the Software during the applicable warranty period and provide evidence of the date you acquired the Software will Opto 22 be obligated to honor this warranty. Opto 22 will use reasonable commercial efforts to replace or refund pursuant to the foregoing warranty within thirty (30) days of being so notified.

THIS IS A LIMITED WARRANTY AND IT IS THE ONLY WARRANTY MADE BY OPTO 22. OPTO 22 MAKES NO OTHER WARRANTY, REPRESENTATION, OR CONDITION, EXPRESS OR IMPLIED, AND EXPRESSLY DISCLAIMS THE IMPLIED WARRANTIES OF MERCHANTABILITY, FITNESS FOR A PARTICULAR PURPOSE, AND NONINFRINGEMENT OF THIRD PARTY RIGHTS. THE DURATION OF IMPLIED WARRANTIES OR CONDITIONS, INCLUDING WITHOUT LIMITATION, WARRANTIES OR CONDITIONS OF MERCHANTABILITY AND OF FITNESS FOR A PARTICULAR PURPOSE, IS LIMITED TO THE ABOVE LIMITED WARRANTY PERIOD; SOME JURISDICTIONS DO NOT ALLOW LIMITATIONS ON HOW

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GNU GENERAL PUBLIC LICENSE

LONG AN IMPLIED WARRANTY OR CONDITION LASTS, SO LIMITATIONS MAY NOT APPLY TO YOU. NO OPTO 22 DEALER, AGENT, OR EMPLOYEE IS AUTHORIZED TO MAKE ANY MODIFICATIONS, EXTENSIONS, OR ADDITIONS TO THIS WARRANTY. If any modifications are made to the Software by you during the warranty period or if you violate the terms of this Agreement, then this warranty shall immediately be terminated. This warranty shall not apply if the Software is used o n or in co njunct ion with ha rdware or software other than the un modi fied versi on of hardware and software with which the Software was designed to be used as described in the documentation.

THIS WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS, AND YOU MAY HAVE OTHER LEGAL RIGHTS THAT VARY FROM STATE TO STATE OR BY JURISDICTION.

LIMITATION OF LIABILITY. UNDER NO CIRCUMSTANCES AND UNDER NO LEGAL THEORY, TORT, CONTRACT, OR OTHERWISE, SHALL OPTO 22 OR ITS SUPPLIERS OR RESELLERS BE LIABLE TO YOU OR ANY OTHER PERSON FOR ANY INDIRECT, SPECIAL, INCIDENTAL, OR CONSEQUENTIAL DAMAGES OF ANY CHARACTER INCLUDING, WITHOUT LIMITATION, DAMAGES FOR LOSS OF GOODWILL, WORK STOPPAGE, COMPUTER FAILURE OR MALFUNCTION, OR ANY AND ALL OTHER COMMERCIAL DAMAGES OR LOSSES, OR FOR ANY DAMAGES IN EXCESS OF OPTO 22’S LIST PRICE FOR THE DEVICE, EVEN IF OPTO 22 SHALL HAVE BEEN INFORMED OF THE POSSIBILITY OF SUCH DAMAGES, OR FOR ANY CLAIM BY ANY OTHER PARTY. THIS LIMITATION OF LIABILITY SHALL NOT APPLY TO LIABILITY FOR DEATH OR PERSONAL INJURY TO THE EXTENT APPLICABLE LAW PROHIBITS SUCH LIMITATION. FURTHERMORE, SOME STATES DO NOT ALLOW THE EXCLUSION OR LIMITATION OF INCIDENTAL OR CONSEQUENTIAL DAMAGES, SO THIS LIMITATION AND EXCLUSION MAY NOT APPLY TO YOU.

TERMINATION. This license will terminate automatically if you fail to comply with the limitations described above. On termination, you must destroy all copies of the Software and documentation.

MISCELLANEOUS/GENERAL. This Agreement represents the complete agreement concerning this license between the parties and supersedes all prior agreements and representations between them. It may be amended only by a writing executed by both parties. THE ACCEPTANCE OF ANY PURCHASE ORDER PLACED BY YOU IS EXPRESSLY MADE CONDITIONAL ON YOUR ASSENT TO THE TERMS SET FORTH HEREIN, AND NOT THOSE CONTAINED IN YOUR PURCHASE ORDER. If any provision of this Agreement is held to be unenforceable for any reason, such provision shall be reformed only to the extent necessary to make it enforceable. This Agreement shall be governed by and construed under California law as such law applies to agreements between California residents entered into and to be performed within California, except as governed by Federal law. The application of the United Nations Convention of Contracts for the International Sale of Goods is expressly excluded.

GNU GENERAL PUBLIC LICENSE

Version 2, June 1991

51 Franklin St, Fifth Floor, Boston, MA 02110-1301 USA

Everyone is permitted to copy and distribute verbatim copies of this license document, but changing it is not allowed.

Preamble

The licenses for most software are designed to take away your freedom to share and change it. By contrast, the GNU General Public License is intended to guarantee your freedom to share and change free software--to make sure the software is free for all its users. This General Public License applies to most of the Free Software Foundation's software and to any other program whose authors commit to using it. (Some other Free Software Foundation software is covered by the GNU Library General Public License instead.) You can apply it to your programs, too.

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APPENDIX C: LICENSING INFORMATION

When we speak of free software, we are referring to freedom, not price. Our General Public Licenses are designed to make sure that you have the freedom to distribute copies of free software (and charge for this service if you wish), that you receive source code or can get it if you want it, that you can change the software or use pieces of it in new free programs; and that you know you can do these things.

To protect your rights, we need to make restrictions that forbid anyone to deny you these rights or to ask you to surrender the rights. These restrictions translate to certain responsibilities for you if you distribute copies of the software, or if you modify it.

For example, if you distribute copies of such a program, whether gratis or for a fee, you must give the recipients all the rights that you have. You must make sure that they, too, receive or can get the source code. And you must show them these terms so they know their rights.

We protect your rights with two steps: (1) copyright the software, and (2) offer you this license which gives you legal permission to copy, distribute and/or modify the software.

Also, for each author's protection and ours, we want to make certain that everyone understands that there is no warranty for this free software. If the software is modified by someone else and passed on, we want its recipients to know that what they have is not the original, so that any problems introduced by others will not reflect on the original authors' reputations.

Finally, any free program is threatened constantly by software patents. We wish to avoid the danger that redistributors of a free program will individually obtain patent licenses, in effect making the program proprietary. To prevent this, we have made it clear that any patent must be licensed for everyone's free use or not licensed at all.

The precise terms and conditions for copying, distribution and modification follow.

GNU GENERAL PUBLIC LICENSE

TERMS AND CONDITIONS FOR COPYING, DISTRIBUTION AND MODIFICATION

0. This License applies to any program or other work which contains a notice placed by the copyright holder saying it may be distributed under the terms of this General Public License. The "Program", below, refers to any such program or work, and a "work based on the Program" means either the Program or any derivative work under copyright law: that is to say, a work containing the Program or a portion of it, either verbatim or with modifications and/or translated into another language. (Hereinafter, translation is included without limitation in the term "modification".) Each licensee is addressed as "you".

Activities other than copying, distribution and modification are not covered by this License; they are outside its scope. The act of running the Program is not restricted, and the output from the Program is covered only if its contents constitute a work based on the Program (independent of having been made by running the Program). Whether that is true depends on what the Program does.

1. You may copy and distribute verbatim copies of the Program's source code as you receive it, in any medium, provided that you conspicuously and appropriately publish on each copy an appropriate copyright notice and disclaimer of warranty; keep intact all the notices that refer to this License and to the absence of any warranty; and give any other recipients of the Program a copy of this License along with the Program.

You may charge a fee for the physical act of transferring a copy, and you may at your option offer warranty protection in exchange for a fee.

2. You may modify your copy or copies of the Program or any portion of it, thus forming a work based on the Program, and copy and distribute such modifications or work under the terms of Section 1 above, provided that you also meet all of these conditions:

a) You must cause the modified files to carry prominent notices stating that you changed the files and the date of any change.

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GNU GENERAL PUBLIC LICENSE

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Index

Numerics

2-pass and 4-pass, 19

AC power, 16 address, 19 analog features

high/low range testing minimum/maximum values, 7 offset and gain calculations, 7 read/write to point in counts, 6 read/write to point in EU, 6 watchdog timer, 7

waveform generation, 7 analog input averaging, 7 analog point, configuring, 45 analog/digital brain board

Modbus function codes supported assigning IP address, 35

, 7

baud rate, 19 biasing, 18 blink codes, 10 board dimensions, 9

cable, 22 COM terminals, 16 communicating with brain board

pinging the brain board communication

handling errors

packet for Modbus/TCP, 42

, 54

, 52

, 42

configuring

analog point digital point, 45 I/O point, 45

connect

Ethernet serial, 16

counters

, 5

Modbus/TCP, 45

, 45

, 21

data

acquisition Modbus float format, 46

DC power, 16 default settings

brain board OmuxSettings file, 67

digital features

counters input latches, 5 pulse duration, 5 pulse generation, 5 read/write to point, 5 time delays, 6

watchdog timer, 6 digital I/O modules, 26 digital point, configuring, 45 dimensions, 9 downloading

OmuxSettings

see loading driver toolkit

, 26, 28

, 35

, 5

, 65

, 31

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E1 brain board

description features, 5 LED descriptions, 10 mounting, 13

E2 brain board

description features, 6 LED descriptions, 10 mounting, 13

errors

codes Ethernet communications, 51 general troubleshooting, 57 Modbus/TCP exception errors, 43 serial communications, 54 troubleshooting communications, 54

Ethernet network

cable specifications certification, 53 connecting, 21 migration options, 32 troubleshooting, 53

exception code, Modbus/TCP, 43

, 1

, 2

, 56

, 22

I/O modules, installing, 16 I/O point

configuring features, Modbus/TCP, 45

input

averaging latches, 5 registers (Modbus), 47

installing

brain board Ethernet, 21 I/O modules, 16 power supply, 15 serial connection, 16 software, 13

ioManager, 52 IP address

assigning resetting to factory default, 35 viewing, 35

IP security, 21

, 45

, 7

, 13

, 35

jumper settings, 18

factory default settings, 35 firmware, loading to brain board, 36 float format, Modbus, 46 format

of Modbus float

of Modbus/TCP communication packet, 42 FTP, 51, 64 function codes, Modbus, 42

, 46

gain, calculating, 7 gain, Modbus/TCP, 46 Group A jumpers, 18 Group B jumpers, 19

help

LED descriptions

network problems, 53

Product Support, 4 high/low range testing, 7 holding registers (Modbus), 47

, 10

kernel, see firmware

latches, Modbus/TCP, 45 LEDs

blink codes

description, 10 licensing, 71 loading new firmware, 36

, 10

maximum value, Modbus/TCP, 46 memory map, Modbus, analog/digital brain boards,

message protocol, 19 minimum /maximum values, 7 minimum value, Modbus/TCP, 46 Modbus float format, 46 Modbus/TCP, 5, 34

communication packet, 42

counters, 45

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exception errors, 43 function codes supported, 42 latches, 45 memory map

analog/digital brain boards

minimum/maximum values, 46 offset and gain, 46 packet, 43 scaling, 46

mounting

brain board racks, 13, 22

multidrop mode, 18

, 13

network

certification OptoEnetSniff, 53 troubleshooting, 53

, 53

offset and gain calculations, 7 offset, Modbus/TCP, 46 OLE, 28 OmuxSettings file, 67 OPC, 28, 33 Opto 22 Product Support, 4 OptoDataLink, 29 OptoEnetSniff, 53 OptoMMP, 5, 31 Optomux, 5, 27 OptoOPCServer, 28, 29, 33

PAC Control, 29 PAC Display, 29 PAC Manager, 29 PAC Project software suite, 29 packet for Modbus/TCP, 42 ping, 52 power supply

analog racks connecting, 15 specifications, 23

Product Support, 4 pulse

duration generation, 5

, 23

, 5

, 46

Quad Pak modules, 26

racks, 14, 22 read/write to point

analog

, 6

digital, 5 reading IP address and subnet mask, 35 registers (Modbus), 47 remote access, 26 remote monitoring, 26 repeat mode, 18 reset brain board, 35 routing table, 63

scaling, Modbus/TCP, 46 security, 21 serial wiring, 16

diagram, 17

migrate to Ethernet, 32

setting jumpers, 17 SNAP digital modules, 26 software, 13 software licensing, 71 specifications, 8 subnet mask, 35

technical support, 4 termination, 18 time delays, 6 troubleshooting

Ethernet communications

general errors, 57

LED descriptions, 10

Modbus exception errors, 43

network, 53

Product Support, 4

serial communications, 54 twisted pair, 16

, 51

UDP, 62 uploading

OmuxRoutes file

OmuxSettings file, 65

, 64

E1 and E2 User’s Guide

Page 94

utilities

OptoEnetSniff

, 53

watchdog timer, 6, 7 waveform generation, 7 wiring

Ethernet serial, 16

, 21

E1 and E2 User’s Guide