Toshiba XLTR-200 User Manual

NETWORK GATEWAY SERIES

ICC

INDUSTRIAL CONTROL COMMUNICATIONS, INC.

XLTR-200

SERIAL MULTIPROTOCOL NETWORK GATEWAY

September 2006 ICC #10604-1.101-000

Introduction

Thank you for purchasing the ICC XLTR-200 Serial Multiprotocol Network Gateway. The XLTR-200 allows information to be transferred seamlessly between many different fieldbus networks with minimal configuration requirements. The XLTR-200 provides two RS485 ports, one RS232 port, and three common serial ports for direct connectivity to Toshiba 7-series, 9-series, 11-series or VF-nC1 Adjustable Speed Drives (ASDs). These various communication ports operate independently, and are configurable along with the unit’s internal point database via a serial console interface.

The gateway currently provides support for the following protocols:

 Modbus RTU (RS485 master & slave)  Modbus RTU (RS232 master & slave)  Toshiba ASD (common serial master)  Toshiba ASD (RS485 master)  Toshiba 3-series ASD (RS232 master)  Mitsubishi 500-series & 700-series ASD (RS485 master)  Siemens FLN (RS485 slave)  Johnson Controls, Inc. Metasys N2 (RS485 slave)

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

Before using the XLTR-200 network gateway, please familiarize yourself with the product and be sure to thoroughly read the instructions and precautions contained in this manual. In addition, please make sure that this instruction manual is delivered to the end user of the XLTR-200, and keep this instruction manual in a safe place for future reference or unit inspection.

This instruction manual describes the device specifications, wiring methods, maintenance procedures, supported functions and usage methods for the XLTR-200 network gateway.

For the latest information, support, firmware releases or product point files, please visit http://www.iccdesigns.com

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

• XLTR-200 gateway

• Panel-mount standoff kit

• Documentation CD-ROM

METASYS IS A REGISTERED TRADEMARK OF JOHNSON CONTROLS, INC.

XLTR-200 Serial Multiprotocol Network Gateway

User's Manual

Part Number 10604-1.100-000

Printed in U.S.A.

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

and improvements to its products without providing notice.

Notice to Users

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

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

Usage Precautions

Operating Environment

• Please use the gateway only when the ambient temperature of the

environment into which the unit is installed is within the following specified temperature limits:

Operation Storage

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

vibrations.

• Avoid installation locations that may be subjected to rapid changes in

tem

: -10 ∼ +50°C (+14 ∼ +122°F)

: -40 ∼ +85°C (-40 ∼ +185°F)

erature or humidity.

Installation and Wiring

• Proper ground connections are vital for both safety and signal reliability

reasons. Ensure that all electrical equipment is properly grounded.

• Route all communication cables separate from high-voltage or noise-

emitting cabling (such as ASD input/output power wiring).

ASD Connections

• Do not touch charged parts of the drive such as the terminal block

while the drive’s CHARGE lamp is lit. A charge will still be present in the drive’s internal electrolytic capacitors, and therefore touching these areas may result in an electrical shock. Always turn all drive input power supplies OFF, and wait at least 5 minutes after the CHARGE lamp has gone out before connecting communication cables.

• To avoid misoperation, do not connect any gateway terminals to either

the ASD’s E/GND terminals, the motor, or to any other power ground.

• When making common serial connections between the gateway and

Toshiba ASDs, do not use cables that exceed 5 meters in length.

• For further drive-specific precaution, safety and installation information,

please refer to the appropriate documentation supplied with your drive.

• Internal ASD EEPROMs have a limited life span of write cycles.

Observe all precautions contained in this manual and your ASD manual regarding which drive registers safely may and may not be repetitively written to.

• When used without an Auxiliary power source (Toshiba ASD common

serial mode), the gateway derives its control power from the connected drives. Therefore, removing power to all connected drives will also cause the gateway to lose power.

TABLE OF CONTENTS

1. The Network Gateway Series Concept.......................................7

2. Feature Summary..........................................................................8

3. Installing the Gateway................................................................10

3.1 Mounting .............................................................................................10

3.1.1 Panel Mounting...............................................................................10

3.1.2 SnapTrackTM Mounting ...................................................................11

3.1.3 DIN Rail Mounting...........................................................................11

3.2 Installation for Non-Toshiba ASD Networks ........................................12

3.3 Toshiba Common Serial ASD Network Installation .............................12

3.3.1 Installation for G7 ASDs..................................................................13

3.3.2 Installation for S7, S9, S11, A7 and VF-nC1 ASDs.........................15

4. RS485 Port Electrical Interfaces ...............................................17

5. Environmental Specifications ...................................................18

6. Maintenance and Inspection .....................................................19

7. Storage and Warranty ................................................................20

7.1 Storage................................................................................................20

7.2 Warranty..............................................................................................20

8. LED Indicators ............................................................................21

8.1 Toshiba ASD Common Serial Port Indicators .....................................21

8.2 RS485 Port Indicators .........................................................................21

9. Configuration Switches .............................................................21

10. Auxiliary Power Supply..........................................................22

11. Unit Configuration Concepts.................................................23

11.1 Port and Protocol Configuration ..........................................................23

11.2 Timeout Configuration.........................................................................23

11.3 Point Configuration..............................................................................24

11.4 General Configuration Procedure........................................................ 25

12. Console Access ......................................................................27

12.1 RS232 .................................................................................................27

12.1.1 Requirements .............................................................................27

12.1.2 Connection .................................................................................27

12.1.3 Application Configuration ........................................................... 28

12.2 Invocation ........................................................................................... 30

12.3 Main Menu.......................................................................................... 31

12.3.1 View/Edit Points ......................................................................... 32

12.3.2 View/Edit Ports .......................................................................... 39

12.3.3 Load Points ................................................................................ 41

12.3.4 Xmodem Point File..................................................................... 41

12.3.5 XLTR-200 Information................................................................ 43

13. Protocol-Specific Information ...............................................44

13.1 Modbus............................................................................................... 44

13.1.1 Coil Mappings ............................................................................ 45

13.1.2 Modbus RTU Slave.................................................................... 46

13.1.3 Modbus RTU Master.................................................................. 46

13.2 Metasys N2......................................................................................... 48

13.3 Toshiba Common Serial ASD Protocol............................................... 51

13.4 Toshiba RS485 ASD Protocol ............................................................ 51

13.5 Mitsubishi ASD Protocol ..................................................................... 54

13.6 Siemens FLN...................................................................................... 58

13.6.1 Ports .......................................................................................... 58

13.6.2 Supported Subpoints ................................................................. 59

13.6.3 Subpoint Details......................................................................... 60

13.7 Toshiba 3-Series ASD Protocol .......................................................... 63

13.7.1 Command Parameters............................................................... 64

13.7.2 Monitor Parameters ................................................................... 65

13.7.3 Fundamental Parameters #1...................................................... 69

13.7.4 Fundamental Parameters #2...................................................... 70

13.7.5 Panel Control Parameters.......................................................... 70

13.7.6 Terminal Selection Parameters.................................................. 71

13.7.7 Special Control Parameters ....................................................... 75

13.7.8 Frequency Setting Parameters .................................................. 76

13.7.9 Protection Function Parameters................................................. 79

13.7.10 Pattern Run Control Parameters ................................................ 81

13.7.11 Feedback Control Parameters ................................................... 84

13.7.12 Communication Setting Parameters .......................................... 85

13.7.13 AM/FM Terminal Adjustment Parameters .................................. 86

13.7.14 Utility Parameters....................................................................... 87

13.7.15 Motor Rating Parameters ........................................................... 89

13.7.16 Inverter Fault Codes .................................................................. 90

14. Firmware Updates...................................................................92

14.1 Requirements ..................................................................................... 92

14.2 Connection ..........................................................................................92

14.3 Using the RFU Utility ...........................................................................93

14.3.1 Required Files ............................................................................93

14.3.2 First-Time Configuration .............................................................93

14.3.3 Transmitting Firmware Files .......................................................94

14.4 Wrap-Up..............................................................................................96

15. Notes ........................................................................................97

1. The Network Gateway Series Concept

The XLTR-200 is a member of the ICC Network Gateway Series product family. Members of this family are designed to provide a uniform interface, configuration and application experience. This commonality reduces the user’s learning curve, reducing commissioning time while simplifying support. The XLTR-200 provides simultaneous support for many different communication protocols, allowing complex interchanges of data between otherwise incompatible networks.

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

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

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

2. Feature Summary

RS485 Ports

Two half-duplex 2-wire RS485 ports (A / B / Signal Ground / Shield). These ports allow a selection of various master and slave protocols.

RS232 Port

One RS232 port that can be used to configure the unit, update the internal firmware, upload/download files or act as a control protocol port.

Toshiba ASD Ports

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

Power Supply

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

Supported Protocols

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

MGI Technologies, Inc. ASDs)

 Siemens FLN (RS485 slave)  Johnson Controls, Inc. Metasys N2 (RS485 slave)

Text-Based Console Configuration

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

Configuration File Upload/Download

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

Network Timeout Action

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

Indicators

• 1 bicolor red/green “MS” LED that indicates module status information.

• 1 bicolor red/green “NS” LED that indicates network status information.

• 1 green “TX” and 1 red “RX” LED on each RS485 port.

• 1 green and 1 red LED on each of the Toshiba common serial ASD ports.

Refer to section 8 for more detailed information about the LED indicators and their meanings.

Field-Upgradeable

As new firmware becomes available, the unit can be upgraded in the field by the end-user. Refer to section 13.6 for more information.

Versatile Mounting Options

The unit can be panel-mounted with the included standoff kit, or snapped into existing 4” Augat SnapTrack

(6TK series or equivalent). An optional mounting kit (ICC part number 10581) is also available for DIN-rail mount applications.

3. Installing the Gateway

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

3.1 Mounting

3.1.1 Panel Mounting

The included standoff kit allows for panel mounting of the unit. The standoff kit is comprised of four 1” aluminum male/female standoffs and four #6 lock washers.

1. Remove one of the four cover standoff retention screws and its lock washer from the bottom side of the unit. DO NOT dispose of this screw and washer, as they will be used later to mount the unit to the panel.

2. Install one of the male/female standoffs and a #6 lock washer from the standoff kit through the unit’s circuit board and into the bottom of the cover standoff. Refer to Figure 1.

gateway unit

anel

lock washers

lock washers and screws from step 1

aluminum standoffs

Figure 1: Standoff Kit Installation

3. Repeat steps 1 and 2 above to replace each of the three other cover standoff retention screws.

4. Using the dimensions provided in Figure 2, drill four 0.150” diameter holes at the specified locations on the panel. As a convenient pattern guide, the unit with attached mounting standoffs can be held against the panel, and the four standoff locations marked with a pencil or scribe.

3.5 IN

4.0 IN

2.9 IN

Figure 2: Standoff Hole Placement

5. As shown in Figure 1, use the four screws and lock washers from step 1 to mount the unit from the back side of the panel.

3.1.2 SnapTrackTM Mounting

The unit footprint measures 4” x 4” square, and is designed to fit directly into existing 4” Augat SnapTrack unit into the SnapTrack the 4 corners of the unit’s cover. DO NOT press directly on the aluminum cover, as this may damage the cover.

(6TK series or equivalent). Carefully insert the

by pressing firmly on the pan head screws located at

3.1.3 DIN Rail Mounting

An optional mounting kit (ICC part number 10581) allows DIN rail mounting of the unit. The mounting kit is comprised of a 4” section of Augat 6TK SnapTrack

1. Carefully insert the unit into the SnapTrack

2. Install the DIN rail clips into the openings on the bottom side of the

and two DIN rail clips.

by pressing firmly on the pan head screws located at the 4 corners of the unit’s cover. DO NOT press directly on the aluminum cover, as this may damage the cover.

SnapTrack

. Refer to Figure 3.

Figure 3: DIN Rail Mounting Kit Installation

3.2 Installation for Non-Toshiba ASD Networks

Note that in order to power the unit when not connecting to Toshiba ASDs via the common serial ports, the optional 120VAC/9VDC power supply (ICC part number 10456) or a user-supplied power source meeting the requirements outlined in section 10 must also be installed.

1. Mount the unit via the desired method (refer to section 3.1).

2. Connect the various networks to their respective plugs/terminal blocks. Ensure that any terminal blocks are fully seated into their respective headers, and route the network cables such that they are located well away from any electrical noise sources, such as ASD input power or motor wiring. Also take care to route all cables away from any sharp edges or positions where they may be pinched.

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

4. Connect the power supply to the gateway’s “AUX PWR” jack.

3.3 Toshiba Common Serial ASD Network Installation

The gateway connects to each drive via the drive’s common serial (logic level) communication port, typically located on either the main drive control board (G7, S11), on the front of the drive enclosure under a small snap-on cover (A7, S9), on the right-hand side of the drive enclosure under a small snap-on cover (S7), or on the bottom side of the drive enclosure (VF-nC1). Although in general no drive parameters need to be configured in order to use the gateway,

it is advantageous to check that the drive’s common serial communication data rate is set to its maximum speed. Because the gateway will communicate to each drive only at the drive’s configured data rate, this will provide the fastest response time for drive-to-network data transfers. For information on checking the drive’s common serial communication data rate, refer to the appropriate manual supplied with your drive.

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

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

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

3.3.1 Installation for G7 ASDs

1. Mount the unit via the desired method (refer to section 3.1).

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

4. Remove the drive’s front cover / open the drive’s cabinet door (refer to the

5. The drive’s LCD panel (also called the “Electronic Operator Interface” or

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

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

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

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

continuing the installation process.

appropriate drive manual for instructions how to do this).

“EOI”) can communicate with the drive via either the RS485/RS232 channel (CNU1/CNU1A) or the common serial channel (CNU2/CNU2A). Because the gateway uses the common serial channel, the LCD panel must be configured to use the RS485/RS232 channel. If the drive to be connected is currently using CNU2 (on the drive control board) and CNU2A (on the LCD panel), then this connection must first be switched

over to CNU1 (on the drive control board) and CNU1A (on the LCD panel). Refer to Toshiba’s documentation for any precautions or notices regarding this connection change. If the LCD panel is already connected via the RS485/RS232 channel, then no change is required.

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

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

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

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

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

10. Connect the other various networks to their respective plugs/terminal blocks. Ensure that any terminal blocks are fully seated into their respective headers, and route the network cables such that they are located well away from any electrical noise sources, such as ASD input power or motor wiring. Also take care to route all cables away from any sharp edges or positions where they may be pinched.

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

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

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

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

1. Mount the unit via the desired method (refer to section 3.1).

4. Remove the drive’s common serial communication port cover if it has one

5. Connect the drive’s common serial communication port to one of the ASD

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

7. Connect the other various networks to their respective plugs/terminal

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

9. Take a moment to verify that the gateway and all network cables have

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

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

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

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

continuing the installation process.

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

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

blocks. Ensure that any terminal blocks are fully seated into their respective headers, and route the network cables such that they are located well away from any electrical noise sources, such as ASD input power or motor wiring. Also take care to route all cables away from any sharp edges or positions where they may be pinched.

“AUX PWR” jack.

sufficient clearance from drives, motors, or power-carrying electrical wiring.

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

4. RS485 Port Electrical Interfaces

In order to ensure appropriate network conditions (signal voltage levels, etc.) when using the gateway’s RS485 ports, some knowledge of the network interface circuitry is required. Refer to Figure 4 for a simplified network schematic of the RS485 interface circuitry. Note that the “Shield” terminal has no internal connection: its purpose is simply to provide a cable shield chaining location between devices. The shield is then typically connected to ground at one location only.

Figure 4: RS485 Interface Circuitry Schematic

Figure 5 details the specific network connections to the RS485 terminal block. This connection scheme applies equally to both RS485 ports.

Signal Ground

Shield

Figure 5: RS485 Terminal Block Connections

5. Environmental Specifications

Item Specification

Indoors, less than 1000m above sea level, do not

Operating Environment

expose to direct sunlight or corrosive / explosive gasses

Operating Temperature

Storage Temperature

Relative Humidity

Vibration

Grounding Non-isolated, referenced to power source ground

Cooling Method Self-cooled

-10 ∼ +50°C (+14 ∼ +122°F)

-40 ∼ +85°C (-40 ∼ +185°F)

20% ∼ 90% (without condensation)

5.9m/s

{0.6G} or less (10 ∼ 55Hz)

6. Maintenance and Inspection

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

Inspection Points

• Check that the network cable(s) are properly terminated in the terminal

block(s), and ensure that pluggable terminal blocks are fully seated in their headers. Reseat if necessary.

• Check that there are no defects in any attached wire terminal crimp points.

Visually check that the crimp points are not damaged or loose.

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

• Clean off any accumulated dust and dirt.

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

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

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

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

7. Storage and Warranty

7.1 Storage

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

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

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

7.2 Warranty

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

8. LED Indicators

The gateway contains several different LED indicators, each of which conveys important information about the status of the unit and connected networks. These LEDs and their functions are summarized here.

8.1 Toshiba ASD Common Serial Port Indicators

Each Toshiba ASD common serial port RJ45 connector has two LEDs positioned immediately above them (1 green and 1 red).

Green LED.......Indicates “drive link”. Solid green when a logical connection

exists with the attached drive (i.e. the gateway is reading data from the drive).

Red LED ..........Data write. Flashes briefly when data is written to the drive

from the point database.

8.2 RS485 Port Indicators

Each RS485 port has one red and one green LED situated next to its respective terminal block.

Green LED.......Lights when the gateway is transmitting data on the port.

Red LED ..........Lights when the gateway is receiving data on the port (note that

this does not indicate the validity of the data with respect to a particular protocol: only that data exists and is being detected.)

9. Configuration Switches

There are two configuration DIP switches (marked “CFG”) located on the unit near the RS232 port.

Switch #1 .........Firmware update switch. Place in “OFF” position for normal

operation, and in the “ON” position only when new firmware is to be downloaded to the unit. Refer to section 14 for more information.

Switch #2 .........RS232 port selection switch. When “OFF” at unit startup, the

RS232 port will act as the serial console, regardless of the port’s configuration or protocol assignment (refer to section 12 for more information on the serial console). When “ON” at unit startup, the RS232 port carries whatever protocol (if any) was assigned to it at configuration time. Note that the state of this switch is only detected when the gateway boots up.

10. Auxiliary Power Supply

The ICC part #10456 120VAC/9VDC power supply can be used to power the unit via the AUX PWR input. If providing your own auxiliary power supply, ensure that it adheres to the following specifications:

Connection diagram ...............

Voltage rating ......................... 9 - 40VDC

Current rating ......................... 500mA (@9VDC)

The gateway’s AUX PWR input uses the CUI, Inc. PJ-002A (2.1mm x 5.5mm) or equivalent DC power jack, which mates with the PP-002A (2.1mm x 5.5mm) or equivalent power plug.

11. Unit Configuration Concepts

11.1 Port and Protocol Configuration

Each of the communication ports can be individually configured or enabled/disabled. It is important to note that the ports function independent of one another, and can operate simultaneously. For example, a Modbus RTU slave request on RS485A, and an ASD1 request can simultaneously the same internal point.

Although each communication port can be configured via the serial console interface, their configuration selections vary slightly. The Toshiba ASD common serial ports have a simple enable/disable selection. The RS232 and RS485 ports can be disabled, or can have one of a selection of control protocols assigned to them.

Along with the protocol selection for the RS232/RS485 ports, each of these ports also has a corresponding baudrate, parity, address assignment and timeout time assignment. Note that not all assignable protocols support the same range of configuration options: therefore be sure to assign a valid entry in all cases (for example, a Modbus RTU slave’s “address” assignment must be in the range 1-247 to comply with the Modbus specification). Also note that certain protocols may not make use of all available configuration options (e.g. certain protocols operate only at one specified baudrate regardless of the “baudrate” selection value). The protocol-specific sections of this manual will document these cases.

access

11.2 Timeout Configuration

The gateway’s points can be configured to perform a specific set of actions when primary communications are lost on one or more of its various networks. This allows each point to have its own unique “fail-safe” condition in the event of a network interruption. There are three separate elements that define the network timeout behavior:

• A port’s network timeout time

• A point’s “Timeout Enable” selection

• A point’s “Timeout Value” setting

The timeout time is adjustable in 1s increments from 0 to 500s.

The default timeout time in all cases is 0, which disables network timeout handling. When nonzero, timeout processing does not begin until after a valid network packet has been received by the unit on that port.

When the timeout time is nonzero and a communication interruption is detected, the timeout enable selections for each point are inspected. Those

points that are found to have their timeout enable selections set to “enabled” will then have their configured timeout values automatically written to their assigned “source port” objects. This mechanism provides for a flexible set of device failsafe conditions to be established on a point-by-point basis.

11.3 Point Configuration

As mentioned in section 1, the Network Gateway Series concept revolves around a central “point database”, containing the value and access characteristics for each network. With respect to the Network Gateway Series, a “point” is simply an object that defines some sort of network access, mapping and configuration data, as well as a single “value” attribute that can be read from or written to by various communication ports or protocols.

The only restriction placed on this “central clearinghouse” concept is that only one port can autonomously update the point’s value, “mirroring” its designated object for other protocols to access. What this means is that although any protocol can read from or write to a point’s internal value, most of the time that point’s value will simply be mirroring a remote data object that resides on one of the gateway’s subnets. The selection of what a specific point is to mirror is performed via its “source port” selection.

For example, a point may be configured to contain Toshiba ASD parameter mapping and Modbus master ID and holding register mapping information. However, because both of these protocols act as “master” protocols, only one of them can be allowed to continuously update the point’s value. If both master protocols could simultaneously update the point’s internal value, it would erratically alternate back and forth between the values designated by the Toshiba parameter and Modbus holding register objects. Any “slave” protocol (Modbus RTU slave, Metasys N2 etc.) can read from or write to a point at any time, but only the protocol designated by the point’s “source port” assignment will autonomously update the point’s value independent of any other protocol traffic.

The “source port” designation also determines where a new point value will be written to when a “slave” protocol writes a new value to the point. For example, if a Modbus RTU slave connection is used to write new data that changes the value of a point, how do we know where this new value will exit the gateway to arrive at its final destination? The answer is that any new point values written by “slave” protocols will generate “write” transactions only on the “source port”.

This concept may best be further explained by way of a representative scenario. For example, let’s assume that the gateway’s RS485A port has been designated to be a Modbus Master. Let’s further assume that the “Modbus Master” portion of point #5 indicates an “Address” value of 8 and “Register” value of 14, and that point #5’s “Source Port” selection is set to “RS485A”. What this means is that independent of any other gateway traffic, point #5 will continuously attempt to update its internal value by making requests to the

RS485A port. And, because the RS485A port has been designated as a Modbus Master, then the “Modbus Master” portion of point #5’s configuration will be referenced by the update task, and point #5’s value will therefore always be mirroring the value of holding register #14 of remote Modbus station address #8 connected to the Modbus subnet attached to the gateway’s RS485A port. Perhaps holding register #14 of Modbus station address #8 is a monitor item, indicating the pressure in compressor tank. Whenever the tank’s pressure changes, therefore, the value of point #5 will automatically update to reflect the new value read from the remote device. Once the tank’s pressure reading has been brought into the gateway, it can then be retrieved by any protocol (or ALL the protocols) currently assigned to the gateway’s other communication ports.

As a modification to the previous example, let’s assume this time that holding register #14 of Modbus remote station address #8 is the speed command of a conveyor belt. In this case, point #5 of the gateway will be mirroring the current speed command of the conveyor, in a similar fashion to how it previously mirrored the compressor tank’s pressure. This time, however, the speed command represents something that can also be written to. Therefore, any new data value that is written to point #5 from any other port connection will automatically cause a “write holding register” transaction to occur on the RS485A Modbus master port, updating the value of holding register #14 on remote Modbus station #8, causing the conveyor to accelerate (or decelerate) to the new speed.

Note that it is also perfectly acceptable to have a point’s “source port” assigned to “NONE”. All this means that this point will not be autonomously updated (i.e. that it will not automatically mirror anything.) In a sense, it will simply be “scratchpad memory” that the various ports and protocols can use to exchange information among themselves.

Although the various configuration possibilities may seem overwhelming at first, it is clear that the gateway can perform powerful and flexible routing algorithms. Through configuration experience, the “in” and “out” data flows will become more clear.

11.4 General Configuration Procedure

Now that we have had a brief tutorial on port and point configuration, we can proceed on to how these elements fit into the overall configuration procedure. The general configuration procedure steps can be summarized as follows:

1. Access the serial console configuration interface via Hyperterminal or other text-based console program.

2. Assign (or enable/disable) the desired protocols and their characteristics to the specific communication ports.

3. Perform the desired per-protocol mapping and definition assignments for each point, including the name, timeout and “source port” assignments.

4. Exit the serial console, which will update the gateway’s internal configuration file and reboot the unit.

5. Download a copy of the unit’s configuration file to your PC for backup purposes

Of course, it is possible to simplify or even eliminate some of these steps by starting your configuration from a pre-existing point database file (either downloaded from the internet or previously-created by the user), and then simply modifying those elements necessary to match your application.

12. Console Access

12.1 RS232

The console is accessible via an RS232 interface for direct connection to a computer’s serial (COM) port. This is performed by connecting the unit’s RS232 port to the computer’s serial port via a standard straight-thru serial cable.

12.1.1 Requirements

All that is needed is a computer with a serial (COM) port containing some sort of communications software (such as HyperTerminal, included with Microsoft Windows operating systems) and a straight-thru serial cable, such as the Belkin 6’ serial extension cable (Belkin part #F2N209-06). Refer to Figure 6 for a representative example cable. Any communications software and PC will work, provided they support ASCII communications at 38.4kbaud.

Figure 6: A Typical Serial Extension Cable

12.1.2 Connection

Connect one end of the serial cable to the gateway’s RS232 port, and connect the other end to the computer’s serial port. Make sure that CFG DIP switch #2 is in the “OFF” (left) position to force the RS232 port to act as the serial console. If the unit is currently using the RS232 port for control protocol communication, then it must be rebooted (powered down and then back up again) with CFG switch #2 in the OFF position to enable the serial console on the RS232 port.

12.1.3 Application Configuration

As previously mentioned, any PC communication software and PC serial port can be used. The software configuration example given here will be for Windows HyperTerminal communicating via COM1.

Figure 7 shows the “Connect To” tab of the properties window for COM1. Figure 8 shows the window that appears when “Configure” is selected in the “Connect To” tab. Figure 9 shows the “Settings” tab of the properties window. Most of these settings are their default values: usually the only change needed is the “Bits per second” setting shown in Figure 8.

Figure 7: HyperTerminal Properties…Connect To

Figure 8: HyperTerminal Properties…Connect To…Configure

Figure 9: HyperTerminal Properties…Settings

+ 69 hidden pages