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XLTR-100 V2.100 User`s Manual

1. 13 4 2 Toshiba ASD Common Serial Secondary Network 14 421 AnstallavOnsOrG7 ASDS is i cote ibis 14 4 2 2 Installation for S7 S9 S11 A7 and VF nC1 ASDSs 16 5 RS 485 Electrical Interface 18 6 Environmental Specifications 19 7 Maintenance and Inspection 20 9 Storage and oe vas US VR 21 8 1 S118112 19 e AAEE BOLEA PORIE EO PRODR ee 21 8 2 21 9 5 22 9 1 Toshiba ASD 22 9 2 MMI Port Indicators ORT ROO p 23 10 Configuration 2 23 11 internal Battery vb dE Ea CE eb 42424100 23 12 Point CORTIGQUMALION usus ene oet exec FU DOS 24 12 1 EN 25 12 2 eli cmt 28 12 3 Network Timeout 5 30 12 4 General Configuration Procedure 31 13 Console ACCOSS spar ba 32 13 1 NET 32 19 2 CONNECCION 32 13 3 Application Configuration 2 2 32 lec 13 4 NW OC AION caters tec ae
2. Network Point Address 1 2 NPT Network Point Type BO1 OFF Value OFF 0 Value 9 0 0080 Figure 39 N2 BO Object Point Diagram Nomenclature The Metasys device type for the gateway is VND e Console object number entry radix is decimal e g 10 1010 54 lec e Because the Metasys N2 protocol specifies strict response timing requirements all accessible data objects must be designated as child points thereby making use of data mirroring e Network characteristics selections not configurable according to the Metasys N2 specification e Because all transactions are handled locally within the gateway write data checking is not available For example if a write to an object is performed and the write data is out of range of the corresponding secondary network object no N2 error will be immediately returned However the N2 object will always reflect the secondary network status and data object value In other words if such an out of range write is performed the unsuccessful secondary side write will be detected and the 2 object s value corrected If COS is enabled for that object the correction will be reported to the NCU upon the next COS poll request e The gateway can be configured to perform a specific set of actions for each AO or BO point when Metasys communications are lost Metasys communications are said to be lost when the gateway do
3. r Point Secondary Network Database Network s Figure 1 The Network Gateway Series Concept 44 2 Mechanical Diagrams 2 1 Enclosure INDUSTRIAL CONTROL COMMUNICATIONS MMI PORT SECONDARY RS 485 4 510 XLIR 100 RS 485 INTERFACE ASD 2 CONFIG PRIMARY RS 485 POWER Figure 2 Enclosure Dimensions units are inches 44 2 2 Mounting Clip 00 200 2 PLCS Figure 3 Mounting Clip Dimensions units are inches lec 2 3 External Interface mm e LO Pd d d x lt LTR 100 gt 4 INTER ACE Configuration Primary AUX Switches RS 485 Power Figure 4 Bottom View Channel Tx LED Rx LED LEDs LEDs MMI port Secondary ASD 1 ASD 2 RS 485 Figure 5 Front View 44 3 Feature Summary Primary Network Half duplex RS 485 A B Signal Ground Shield Secondary Network The XLTR 100 has two independent secondary networks depending on the application e Toshiba ASD common serial The XLTR 100 provides support for simultaneous connection of two Toshiba 7 series 9 series 11 series or VF nC1 ASDs via the drives common serial aka logic level communication ports 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 to connect the XLTR 100 to the drives
4. Space Emulation Telnet terminal ID ANSI Backscroll buffer lines Play sound when connecting or disconnecting Input Translation ASCII Setup Figure 17 HyperTerminal Properties Settings 34 44 13 4 Invocation The console provides standard access and editing methods for the various configuration items points and their associated attributes It is important to note that unless otherwise indicated any modifications made to the point database will become effective immediately However these changes will only be permanently retained when the current database is saved to a file location if a change is made to the database and then the gateway is reset without saving those changes then the active file will be restored upon initialization overwriting the unsaved changes To enter the console simply type menu and press the Enter key You will then be notified that all communication tasks will be terminated for the duration of the editing refer to Figure 18 It is important to ensure that all connected devices are in a safe state such that loss of communications will not pose a danger to equipment or personnel Exiting the console will reset the gateway and restart network communications using the currently active database file At most console prompt locations typing will return you to the previous menu and typing menu will return you to the main menu Al
5. 35 13 5 Ment 36 13 5 1 VIOW EOIT POINTS R 37 13 5 2 43 13 3 3 EOC FOI S 44 13 5 4 NOW etd oh teh oi ge A 45 13 5 5 46 13 5 6 XE PRSTOOIDIOFISOR 49 1 3 9 7 EXIT TRO SAMI 25 22 5225522255 5 sien 49 14 Network Specific Information 50 14 1 Primary Networks 50 14 1 1 MOODUSS DU 50 14 1 2 MOLaSVS sott 53 14 2 Secondary NetWOTIKS Eiai 56 14 2 1 MOGODUS TS TU dett poda EN RENS 56 14 2 2 TOSIDS EFOIOCOL s tmt te au ea RUP En ue 57 14 2 3 Mitsubishi 58 14 2 4 Sullair Supervisor 2 2 1000 000000000000 61 15 Firmware Updates oritur sosta eua 63 15 1 Requirements rnain EET 63 15 2 CORTE COM e sae 63 15 3 Using the RFU 64 15 3 1 cnm 64 15 3 2 First Time Configuration 64 15 3 3 Transmitting Firmware Files esses 66 TOA Wap T 67 16 68 44 1 Network Gateway Series Conc
6. Network Point Type Multiplier Figure 36 N2 Al Object Point Diagram Nomenclature Analog output AO objects are used for setting and monitoring analog control and configuration items An AO value can be modified by issuing an override command Issuing a release command will not cause the AO to automatically return to its pre override value nor will the AO automatically return to its pre override value after a certain time period of no communication A multiplier value is associated with the object and the floating point AO value is divided by this multiplier to produce the secondary network data result secondary side data value AO value multiplier The AO point diagram nomenclature is as indicated in Figure 37 Network Point Address 1 2 AO Network Point Type Ae Multiplier Figure 37 N2 AO Object Point Diagram Nomenclature Binary input Bl objects are used for monitoring discrete digital status items Bl objects support COS alarm enabling and normal alarm status 53 44 indications A object will accept override command but will not change its actual value or indicate override active A bit mask is associated with the object and is used to determine the current state of the BI by inspecting the child s secondary network data at the bit location indicated in the bit mask If the indicated bit is a 1 then the Bl s current state is set to 1 Else itis set t
7. X LK Cancel Help Figure 47 Flash File Selection Window While downloading the RFU utility will indicate the download status Once complete summary information will be displayed in the bottom status bar see Figure 48 TI Time 67 375 seconds 193183 of 193183 bytes sent Figure 48 Summary Information 15 4 Wrap Up Once downloading is complete close the RFU utility move CONFIG switch 4 back to the OFF up position to exit firmware download mode and cycle power momentarily to the unit by either disconnecting the auxiliary power supply and or powering down all connected drives or momentarily removing all drive communication cables from the unit When the unit powers up again it will be running the new application firmware If the new firmware version release notes indicated that point files might need to be reloaded then do so at this point When completed with MMI port use remove the MMI cable and replace the MMI port dust cover to minimize contamination of the port s electrical contacts 67 1 16 4 1 D 1 i 1 4 1 i 1 i 4 1 1 1 NE 4 1 enne B 68 1 1 eme io qu
8. RS 485 Same properties as primary network Power Supply When connected to Toshiba ASDs via the ASD 1 ASD 2 ports can be either powered directly from the attached ASDs or from the auxiliary POWER input jack All other connections RS 485 to RS 485 require the use of the auxiliary POWER input Supported Protocols e Primary Network RS 485 o Modbus RTU o Metasys N2 Secondary Network o Toshiba ASD common serial o Modbus RTU RS 485 o Sullair Supervisor RS 485 o Mitsubishi ASD RS 485 New network drivers are continuously being added and can be downloaded for free from our web site Text Based Console Configuration The unit is configured via a text based console interface available over RS232 by using the included MMI cable and a standard PC terminal program such as Microsoft Windows HyperTerminal Point File Based Configuration Up to 3 point files primary secondary network mapping definition files can be stored in the unit s internal battery backed file system Point files can also be uploaded from downloaded to a PC which provides the capability for PC based file backup and easy configuration copying to multiple units Sample 10 44 point files and related documentation can also be downloaded from our web site uploaded to a unit and custom modified to suit a specific application Drive AutoScan Algorithm Toshiba ASD common serial port connections are automatically establish
9. Create parent points Create child points under parents Save the newly created point database to the gateway s file system and download a copy to your PC for backup purposes 7 Exit the console resets the gateway ooo 59 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 31 44 13 Console Access As mentioned in section 1 the gateway s functionality is entirely controlled by a point database that is user modifiable The method of accessing this database is via a text based console interface over an RS232 connection to a computer s serial COM port This connection is performed by using the included DB9 RJ45 cable to connect the gateway s MMI port to the computer s serial port 13 1 Requirements All that is needed is a computer with a standard serial COM port some sort of communications software such as HyperTerminal included with Microsoft Windows operating systems and the included MMI cable ICC part number 10425 Any communications software and PC will work provided they support ASCII communications at 38 4kbaud 13 2 Connection The gateway ships from the factory with a dust cover installed in the MMI port To minimize contamination of the port s electrical cont
10. File Locations menu item from the main screen The Choose File Locations window shown in Figure 45 then appears Confirm that the correct paths to the referenced files are entered Enter the correct paths if necessary 65 44 Choose File Locations File Locations Cold Loader CAICCARFUScaldload bin Pilot BIOS C AICCARFU pilot bin Flash table CAICCARFU Slash ini Help Figure 45 Choose File Locations Window 15 3 3 Transmitting Firmware Files When a board support package BSP has been downloaded and unzipped the flash firmware file will be the one with BIN as its file name extension Once the RFU utility has been configured the flash firmware files can be downloaded to the gateway by two different methods The simplest way is to drag the application firmware BIN file s icon and drop it onto the RFU 5 main screen This will automatically initiate the download process Alternatively select the File Load Flash Image menu item refer to Figure 46 mi Rabbit Field Utility 2 40 Setup Help Figure 46 Load Flash Image Menu Selection The flash image BIN file selection window will then appear refer to Figure 47 Browse to the location of the flash image file and select it Clicking will then initiate the download process 66 44 Choose Flash Image Flash Image File Location CSICCADNET1004V1 000 BIN
11. refer to Figure 12 this child will be created under this parent From the Metasys NCU s perspective the frequency command is an analog output AO object and it will have a multiplier of 0 01 writing a Metasys value of 10 50Hz for example will therefore result in write data on the Modbus secondary network of 105040 0 041 28 44 Table 1 Example Secondary Network Data Modbus Address Modbus Register Note 5 Frequency command 1 0 01 2 Operating frequency 1 0 01 2 4 Run Stop command run 0x0080 Run Stop status running 0x0080 7 Temperature sensor 1 0 1 Digital output ON 0x0001 9 8 Voltage monitor 1 171v 9 Voltage monitor 2 1 1v Voltage monitor 3 1 1v 11 5 8 13 Voltage monitor 1 1 1v 59 Voltage monitor 2 1 1v zx e Voltage monitor 83 121v Therefore we would need to create this child as indicated in Figure 13 This manual will use the graphical convention of a smaller unbolded circle with a line down the middle to represent a child The numbers or letters on the left of the line will indicate the primary network characteristics object type index multiplier etc and the number on the right will indicate the corresponding secondary network object index Modbus register number for example The specifics of these elements will be discussed later in this manual AO1 0 01 1 eo Figure 13 Child Point In a similar manner the remaining children can be
12. ASD s configured characteristics Any defined children will be continuously read by the gateway for data mirroring When allowed by the primary network protocol primary network requests that target ASD parameters not declared as children will generate secondary network traffic only on demand All parameter writes use the drive s RAM EEPROM data write W command For all writes that target the drive s EEPROM be sure to follow Toshiba s guidelines regarding the number of times a specific parameter can be written without risk of EEPROM damage Console parameter number entry radix is hexadecimal e g 10 0x0010 or 1640 57 44 14 2 3 Mitsubishi Protocol The gateway acts as a Mitsubishi protocol master via the secondary RS 485 port Adjustable speed drives such as the FR A500 E500 F500 series that support the Mitsubishi protocol can be accessed The gateway can connect to the ASD via either the PU panel connector or via an optional FR A5NR computer link board Because the ASDs externally present a 4 wire RS 485 network connecting them to the gateway requires jumpering the network wires for 2 wire format i e connecting SDA RDA and SDB RDB When Using an FR A5NR Card Connect as shown in Figure 40 SDB RoA Rog ROR se A B Signal TB 1 TB 2 Ground TB 3 Figure 40 5 Connections When Using the PU Port Connecting to the drive s RJ 45 PU port will likely require building a c
13. Verify that the CHARGE LED has gone out before continuing the installation process 3 Attach the mounting clip and gateway enclosure in your desired manner refer to page 11 for more information 14 44 4 Remove the drive s front cover open the 5 cabinet door refer to the appropriate drive manual for instructions how to do this The drive s LCD panel also called the Electronic Operator Interface or 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 CNUA2A 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 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 Connect the drive s common serial communication port CNU2 to one of the ASD channels of the gateway with the communication cable communication
14. causes it to become the active file which means that it will automatically be loaded from the file system into the gateway s working memory every time the gateway subsequently boots up Refer to Figure 28 for an example of loading file 2 to 2ASD 2 to 2ASD will then also become the active file and will be the configuration loaded into the gateway s working memory at the beginning of the next boot cycle 44 1 Direct Hyper Terminal File Edit View Call Transfer Help gt View Edit Points Save Points Load Points New Points Xmodem Point File ALTR 180 Information Exit amp Restart gt 3 Main Menu gt Load Points fissy Line 6 gt N2_to_2ASD gt gt 6 11 11 38400 8 1 Figure 28 Loading a Point File 13 5 4 New Points Main menu selection number 4 is used to begin a new configuration from scratch When selected a prompt will be displayed indicating that the current configuration in the gateway s working memory will be cleared refer to Figure 29 The console will then prompt for the primary and secondary networks as an example Modbus RTU is being selected for the primary network protocol in Figure 29 This action will clear all parent and child points necessitating the general configuration process outlined in section 12 4 to add parents and children configure network characteristics save the point file etc Because the point
15. created under each respective parent resulting in the final network diagram as shown in Figure 14 While the mapping function provided by children may be obvious there is another less apparent service provided by children This service is termed data mirroring whereby current copies of point values secondary network object data are maintained locally within the gateway itself This greatly reduces the primary network s request to response latency time as requests read or write can be entirely serviced locally thereby eliminating the time required to execute a secondary network transaction As will be later discussed in the network specific sections of this manual primary networks with strict response time requirements such as Metasys N2 must use data mirroring and therefore must have all accessible data objects explicitly declared as children in order to ensure that response time specifications are met Primary networks without such time requirements such as Modbus RTU may still use data mirroring to optimize network bandwidth but are not required to do so BO1 OFF 0 120 ON 0x0080 Figure 14 Completed Example Configuration 12 3 Network Timeout Settings The gateway can be configured to perform a specific set of actions when primary network communications are lost This allows each internally defined child point to have its own unique fail safe condition in the event of a primary network interruption There are
16. data objects the additional parameter numbers indicated in Table 4 have been assigned For further information on these parameters please refer to the relevant Mitsubishi documentation Table 4 Additional Mitsubishi Parameter Assignments Parameter item Number 1000 Second parameter switch over 1001 Frequency command RAM 1002 Frequency command EEPROM 1003 Frequency monitor 1004 Output current monitor 1005 Output voltage monitor 1006 Special monitor 1007 Special monitor selection number 1008 Most recent 1 and 82 alarms alarm clear 1009 Most recent 3 and 4 alarms 1010 Most recent 5 and 6 alarms 1011 Most recent 7 and 8 alarms 1014 Inverter status monitor operation command 1015 Operation mode acquisition 1016 All parameter clear 1017 Inverter reset e defined children will be continuously read by the gateway for data mirroring When allowed by the primary network protocol primary network requests that target parameters not declared as children will generate secondary network traffic only on demand ASD communication characteristics are dictated by parameters 117 124 PU port and 331 342 5 interface Most of these parameters can be set as desired by the user However the following parameters must be set as indicated to successfully connect to the gateway Parameter 119 333 stop bits data bits Must be set for 8 data bits Parameter 123 337 wait time setting Must be se
17. database is constructed uniquely for a specific primary secondary network combination it is necessary to create a new point setup anytime the primary or secondary network protocol is changed or alternatively one could start with an existing point setup file with the desired primary and secondary network protocols already selected and then modify the point definitions to fit the target application After configuration has been completed always remember to save the new point setup to the gateway s file system prior to restarting Otherwise the currently active file will be restored from the file system upon boot up overwriting the newly created setup 45 COM1 Direct Hyper Terminal File Edit View Call Transfer Help gt Main Menu View Edit Points Save Points Load Points New Points Xmodem Point File ALTR 180 Information Exit amp Restart gt Main Menu gt New Points Starting a new setup will reset the current point setup To continue choose a primary network protocol Modbus gt 1 Metasys gt 2 Cancel gt 51 6 14 00 ANSIV 38400 8 1 Figure 29 Beginning a New Setup 13 5 5 Xmodem Point File Main menu selection 5 provides a method to upload and download point files to from your PC via the Xmodem protocol Xmodem is a data transfer protocol supported by virtually all terminal emulation programs such as HyperTerminal Whenever a custom point setup
18. is created it is highly recommended that a backup copy of the file be downloaded to a PC in case it becomes necessary to restore it to the gateway s file system later such as if the gateway s internal backup battery fails and requires replacement Two different variations of the Xmodem protocol are supported CRC and Checksum for those terminal emulation programs that only support one or the other This menu selection is also useful for copying point files from one gateway to another or for uploading pre configured point files that have been obtained from the ICC website Figure 30 shows an example of initiating the download of the file Assy Line 6 from the gateway s file system to the PC Once the file to download has been chosen the console will indicate that the gateway is now ready to transmit the file At this point you have 30 seconds in which to initiate the receive function of your terminal emulation program before the gateway will timeout the transaction and return to the main menu prompt In HyperTerminal the receive function can be selected by the 3 icon in the toolbar This will bring up a dialog box Figure 31 that allows you to select the 46 44 destination and the transfer protocol Xmodem Lastly you will be prompted for a filename which the point file will be saved under Figure 32 1 Direct Hyper Terminal TER File Edit View Call Transfer Help Main Menu gt Xmodem Point File Enter
19. reinstalled to minimize contamination of the port s electrical contacts if the gateway is ever disconnected from the drive 5 Connect the drive s common serial communication port to one of the ASD channels of the gateway with the communication cable communication cable is not included with the gateway kit When choosing cables for this connection standard 24 AWG category 5 5 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 5 UTP cables available ICC strongly recommends using only high quality cables from reputable manufacturers to guarantee optimal noise immunity and cable longevity Ensure that each end of the cable is fully seated into the modular connectors and route the cable such that it is located well away from any drive input power or motor wiring Also take care to route the cable away from any sharp edges or positions where it may be pinched 6 Repeat steps 1 2 4 and 5 to connect other drive s as needed 7 Connect the primary network to the Primary RS 485 pluggable terminal block Refer to section 5 for detailed connection information Ensure that the terminal block is fully seated into the terminal block header and route the network cable such that it is located well away from any drive input 16 lec power or motor wiring Al
20. selected however then the child type could be AO BO Al or BI 40 1 Direct Hyper Terminal File Edit View Call Transfer Help 121 1 Main Menu gt Edit Points gt Edit Parent N2 051 RTU Reg number number I 1 124 N2 Address 1 Address 1 255 RTU Address 1 TU Address 1 247 Edit a Child BI AO BO 2 obj num 1 256 Add a New Child BI 80 B01 2 obj num 1 256 RTU reg num 1 65535 Delete a Child 0 N2 obj num 1 256 More Children Previous Menu 25 R0 1 Connected 2 59 35 ANSIW 38400 8 N 1 Figure 24 Delete a Child 13 5 1 1 6 More Children The children table displays the mapping information for 5 children at a time If more than 5 children are available in the current configuration menu selection number 6 will display the next 5 children in the list When all children have been displayed entering menu selection number 6 will roll back around to the first 5 children again 73 5 1 2 Add a New Parent To add a new parent to the configuration enter menu selection number 2 with the additional arguments of the parent s primary and secondary network addresses For example the bottom of Figure 25 shows an example of adding a new parent to map Metasys N2 address 4 to Modbus RTU address 9 The semantics of the menu prompt and allowable address ranges vary depending on the currently active networks Once the new parent has been added to the parent list it
21. three separate elements that define the network timeout behavior e network timeout time refer to section 13 5 1 5 Achild point s Timeout Enable setting refer to section 13 5 1 1 3 Achild point s Timeout Value setting refer to section 13 5 1 1 3 The timeout time is adjustable in 1s increments from 0 to 5005 The default timeout time 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 30 44 When the timeout time is nonzero and communication interruption is detected the timeout enable selections for all configured child points 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 corresponding secondary network objects This mechanism provides for a flexible set of device failsafe conditions to be established on a point by point basis 12 4 General Configuration Procedure Now that we have had a brief tutorial on parents and children 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 Enter the console this stops all network communication tasks 2 Define a new point setup by selecting the primary and secondary protocols Modify network characteristics if necessary
22. to a flat panel via the two bolt holes at the top and bottom of the clip Refer to section 2 2 for mounting clip mechanical details Once the mounting clip is securely attached to the panel the unit enclosure can be snapped onto the clip s retaining tabs For fixed DIN rail mounting a combination of the above two techniques can be employed First snap the mounting clip onto a DIN rail and position it in its desired location Then the mounting clip can be bolted to the DIN rail support panel securing it in place Lastly the unit can be snapped onto the fixed mounting clip 44 In cases the unit can be easily unsnapped from the mounting clip to temporarily provide easier access to the configuration switches or network connector 12 44 4 Installing the Interface The installation procedure of the XLTR 100 will vary slightly depending on the chosen secondary network 4 1 RS 485 Secondary Network Note that in order to power the unit when using the secondary RS 485 network you must also purchase the optional 120VAC 9VDC power supply part number 10456 1 Attach the mounting clip and unit enclosure in your desired manner refer to page 11 for more information Connect the primary network to the Primary RS 485 pluggable terminal block Refer to section 5 for detailed connection information Ensure that the terminal block is fully seated into the terminal block header and route the network cable suc
23. to register bit relationship can be described as follows For any given coil the holding register in which that coil resides can be determined by coil 15 Equation 1 holding register 8 reg 16 Where the bracket symbols L indicate the floor function which means that any fractional result or is to be discarded with only the integer value being retained Also for any given coil the targeted bit in the holding register in which that coil resides can be determined by bit coil 1 16 Equation 2 Where 1 65535 bit 0 15 and 9e is the modulus operator which means that any fractional result or is to be retained with the integer value being discarded i e it is the opposite of the floor function From these equations it can be seen that the largest holding register number that can be accessed via this coil to register mapping method is 4096 which contains coil 65535 For clarity let s use Equation 1 and Equation 2 in a calculation example Say for instance that we are going to read coil 34 Using Equation 1 we can determine that coil 34 resides in holding register 3 as 3 0625 3 r1 3 Then using Equation 2 we can determine that the bit within holding register 3 that coil 34 targets is 34 1 16 1 as 339616 mod 3 r1 1 Therefore reading coil 34 will return the value of holding
24. will always be sent to defined parent addresses Otherwise when allowed by the primary network protocol primary network requests that target Supervisor parameters not declared as children will generate secondary network traffic only on demand e Network characteristics selections no configuration is possible The baud rate is fixed at 9600 baud e The gateway Supervisor interface is primarily a system monitor and configuration device As such the following native Supervisor network commands are not accessible 5 Stop U Unload L Load modulate F Full load T Trim modulate E Emergency stop D Display message A Auto run mode C Cont run mode e Console parameter number entry radix is decimal e g 10 1010 62 44 15 Firmware Updates The gateway s embedded firmware resides in flash memory that can be updated in the field Firmware updates may be released for a variety of reasons such as custom firmware implementations firmware improvements and added functionality as a result of user requests ICC is continually striving to enhance the functionality and flexibility of our products and we therefore periodically release new embedded firmware to achieve these goals and meet customer requests Flash firmware files and all related documentation such as updated user manuals can be downloaded as complete board support packages referred to as BSPs from http www iccdesigns com It is sug
25. 21 48 0 22 36 ANSIW 38400 8 N 1 Figure 21 Edit a Parent 13 5 1 1 1 Edit Primary Network Address Menu selection number 1 allows you to change the current parent s primary network address For example the bottom of Figure 21 shows an example of changing a parent s primary network address to 34 13 5 1 1 2 Edit Secondary Network Address Menu selection number 2 allows you to change the current parent s secondary network address The entry method is similar to that for the primary network address described in section 13 5 1 1 1 38 44 13 5 1 1 3 Edit a Child Entering menu selection number 3 with the additional arguments of the child s type and primary network object number will display a submenu that allows editing of various child characteristics For example the top of Figure 22 shows an example of editing Metasys N2 binary output BO 1 The child type varies depending on the primary network selected For example with a Modbus RTU primary network the child type will always be for register If a Metasys N2 primary network is selected however then the child type could be AO BO Al or BI COM1 Direct Hyper Terminal File Edit View Call Transfer Help 3 bo 1 Main Menu gt Edit Points gt Edit Parent gt Edit Child N2 Address 1 Address 1 Type BO 2 Obj 1 N2 obj num 1 256 RTU Reg 2 RTU reg num 1 65535 ON Value 1 RTU Reg value OFF V
26. NETWORK GATEWAY SERIES icc INDUSTRIAL CONTROL COMMUNICATIONS INC XLTR 100 RS 485 MULTIPROTOCOL NETWORK GATEWAY December 2004 10484 2 100 000 44 Introduction Thank you for purchasing the ICC XLTR Translator 100 RS 485 Multiprotocol Network Gateway The XLTR 100 allows information to be transferred seamlessly between different fieldbus networks with minimal configuration requirements The XLTR 100 provides dual RS 485 network connections a primary slave and a secondary master port as well as two independent 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 currently provide support for the following networks Modbus RTU RS 485 master and slave Johnson Controls Inc Metasys 2 RS 485 slave Sullair Supervisor network RS 485 master Toshiba ASD common serial master Mitsubishi ASD RS 485 master v v New network drivers are continuously being added and can be downloaded for free from our web site Before using the XLTR 100 network gateway please familiarize yourself with the product and be sure to thoroughly read the instructions and precautions contained in this manual In addition please make sure that this instruction manual is delivered to the end user of the XLTR 100 and keep this instruction manual in a safe place for future reference or unit inspection This inst
27. acts keep this dust cover in place whenever the MMI port is not in use Connect the RJ45 end of the MMI cable to the MMI port and connect the other end to the computer s serial port 13 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 1 Figure 15 shows the Connect To tab of the properties window for 1 Figure 16 shows the window that appears when Configure is selected in the Connect To tab Figure 17 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 16 32 lec COM1 Direct Properties Connect Settings Direct Change Enter the area code without the long distance prefix Area code Connect using COMM 1 Use country region code and Redial an buzy Figure 15 HyperTerminal Properties Connect To 1 Properties Fort Settings Bits per second Data bits Parity Stop bits Flow contral Figure 16 HyperTerminal Properties Connect To Configure 33 44 1 Direct Properties Connect Settings Function and ctrl keys act as Windows keys Backspace key sends Cul H Del
28. alue 0 RTU Reg value Timeout Enable V N Timeout Value OFF OFF Previous Menu gt 6 on Connected 3 35 33 ANSIW 38400 8 N 1 Figure 22 Edit a Child Primary Network Object Number Submenu selection number 1 allows modification of the primary network object number An example of changing the point shown in Figure 22 from BO 1 to BO 8 would be 1 8 Secondary Network Object Number Submenu selection number 2 allows modification of the secondary network object number An example of changing the point shown in Figure 22 from holding register Z2 to holding register 123 would be 2 123 Other Attributes The first two selections in the Edit a Child menu will always be as indicated above The remainder of the selections however will vary depending on the child s type Metasys N2 binary output objects for example will allow configuration of the point s ON value OFF value Timeout Enable and Timeout Value Refer to Figure 22 for an example of selecting BO 1 s timeout value to 39 44 13 5 1 1 4 Add a New Child To add a new child to the configuration enter menu selection number 4 with the additional arguments of the child s type the child s primary network object number and the child s secondary network object number For example Figure 23 shows an example of adding a new child to map Modbus holding register 11 to Toshiba ASD parameter FE14 The semantics of the menu prompt and allo
29. any configuration changes are performed they are performed only on the gateway s working memory and that those changes will be lost unless they are saved to the gateway s file system prior to exiting the console The saved file also becomes the new active file which means that it will automatically be loaded from the file system into the gateway s working memory every time the gateway boots up The gateway provides space for three independent files to be stored Refer to Figure 27 for an example of saving the current configuration to file system location 1 with the name Assy Line 6 Assy Line 6 will then also become the active file and will be the configuration loaded into the gateway s working memory at the beginning of the next boot cycle 43 COM1 Direct Hyper Terminal File Edit View Call Transfer Help gt x Hain Menu Xmodem Point File ALTR 180 Information Exit amp Restart 2 Main Menu gt Save Points Choose the file to replace New File Name 15 chars max New File Name 15 chars max New File Name 15 chars 1 fissy Line 6 Connected 6 08 12 38400 8 1 Figure 27 Saving Point File 13 5 3 Load Points Main menu selection number 3 allows the retrieval of a configuration file from the gateway s file system into its working memory The configuration can then be modified while in the working memory and saved back to the file system if desired Loading a file also
30. ateway and all primary and secondary network cables have sufficient clearance from drives motors or power carrying electrical wiring 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 15 44 function properly immediately turn power OFF Repeat steps 1 and 2 to remove all power from the drives Then verify all connections Contact ICC or your local Toshiba representative for assistance if the problem persists 4 2 2 Installation for S7 S9 S11 A7 and VF nC1 ASDs 1 CAUTION Verify that all input power sources to the drives to be connected have been turned OFF and are locked and tagged out 2 DANGER Wait at least 5 minutes for the 5 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 3 Attach the mounting clip and gateway enclosure in your desired manner refer to page 11 for more information 4 Remove the drive s common serial communication port cover if it has one refer to the appropriate drive manual for instructions how to do this Do not discard this cover as it should be
31. 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 Reinstall the drive s front cover close the drive s cabinet door Repeat steps 1 8 to connect other drive s as needed Connect the primary network to the Primary RS 485 pluggable terminal block Refer to section 5 for detailed connection information Ensure that the terminal block is fully seated into the terminal block header and route the network cable such that it is located well away from any 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 If an auxiliary power supply is going to be used connect it to the J 11 gateway s Power jack Take a moment to verify that the g
32. ch conveys important information about the status of the unit and connected networks These LEDs and their functions are summarized here 9 1 Toshiba ASD Port Indicators Each Toshiba ASD port RJ45 connector contains two integrated green LEDs Figure 8 indicates the functions of these LEDs Network Access Drive Link Solid green when a logical connection exists with the attached drive Blinks in 0 1s long bursts when drive is accessed by primary network master Figure 8 Drive Connector Indicators The Network Access indicator is useful for confirming that a specific drive channel is being accessed correctly by the primary network while the Drive Link indicator provides an easy method of determining that the XLTR 100 and drive are successfully exchanging data independent of primary network activity Note Drive Link LED will only represent last access status if no child points are defined for that channel 22 44 9 2 MMI Port Indicators The MMI port RJ45 connector also contains two integrated green LEDs Figure 9 indicates the functions of these LEDs RS 485 Transmit Indicator Blinks in 0 1s long bursts when secondary RS 485 network requests are being transmitted by the gateway RS 485 Receive Indicator 1 Blinks in 0 1s long bursts when secondary RS 485 network responses are being received by the gateway Figure 9 MMI Port Indicators 10 Configuration Switches There are fou
33. ciated with a child depend on primary network and the type of child While a child on a Modbus to Toshiba network may require only two pieces of information Modbus register and corresponding drive parameter a child on a Metasys to Toshiba network will require more information Al multiplier value BO on off write data etc These variations will be discussed later during the individual network issues section At this point one may ask how do know where the individual objects reside on the different networks The answer to that question lies in each child s parent Children are always owned by a parent the parents determine the address to address mapping while the children determine the object to object mapping within the parents address to address mapping space Parents can have as many children assigned to them as required to access all the necessary objects on the secondary network devices up to the maximum number of points available which is 100 As a continuation of the Metasys to Modbus network described in the previous section let s assume that the data shown in Table 1 is to be accessed on each of the Modbus devices and that the data s characteristics are as indicated From this table we notice that in total 12 children must be created Let s begin by creating our first child which will map to Modbus register 10 frequency command on Modbus address 5 Because Modbus address 5 is mapped via a parent to Metasys N2 address 1
34. ddresses No other devices gateways or otherwise can be assigned primary network addresses that have already been assigned to the primary side of parents in a gateway e Primary and secondary network parent addresses must be unique The gateway will not allow the same parent address to be used more than once e g you cannot create a parent mapping address 1 to address 5 and then attempt to create another parent mapping address 1 to address T e If the Toshiba common serial secondary network physical layer is selected then ASD 1 and ASD 2 are the only options available for secondary network addresses Any addressing entered via the drive s panel inverter number parameter for example has no relevance to how that drive is accessed by the gateway e Based on the two previous points it can be seen that applications using the Toshiba common serial secondary network physical layer can have at most two existing parents some address mapping to ASD 1 and some other address mapping to ASD 2 e Secondary network device address assignment is relevant only from a logical or network organizational standpoint Because the primary network master never sees the true secondary network address assigned to a device the secondary network address assignment can be determined by any user defined criteria physical unit position on the floors of a building for example while allowing the primary network address assignment to be ch
35. dren the primary network object number and the secondary network object number The bottom half of the screen contains the menu options for editing the child points 37 44 Whenever new parent point is added refer to section 13 5 1 2 no children are assigned to that parent One must therefore navigate to the Edit a Parent submenu in order to add to or modify that parent s child point configuration Throughout the console note that the entry and display radices of the primary and secondary network data objects depend on the chosen networks For example entering an ASD param number of 10 when the Toshiba ASD secondary network is selected will map a child to ASD parameter 0x0010 1610 However entering an reg num of 10 when the Modbus network is selected will map a child to holding register 1040 These radices are chosen based on the natural radix defined for each protocol For more information on the natural radices of the available networks refer to section 14 COMT Direct HyperTerminal File Edit Call Transfer Help 1 1 Main Menu gt Edit Points gt Edit Parent RTU Reg ASD Param type number number 1 000 RTU fiddress 1 RTU fiddress 1 2471 ASD Address ASD ASD Address ASD1 85021 Edit a Child REG RTU reg num 1 65535 Add a New Child REG RTU reg num 1 655351 ASD param 8 FFFF Delete a Child REG RTU reg num 1 655351 More Children Previous Menu
36. e must create a parent point for each Modbus device four total The secondary addresses of the parent points must of course be the respective pre assigned Modbus addresses 5 7 9 and 11 but the parents provide flexibility in assigning the primary network addresses to be any valid addresses supported by the network Let s say that we would like the NCU to be able to access the four devices with Modbus network addresses 5 7 9 and 11 at Metasys network addresses 1 2 3 and 4 respectively Metasys Address Maps To Modbus Address 1 5 2 7 E 9 11 25 44 Therefore we would need to create our parent points as indicated Figure 12 this manual will use the graphical convention of a large bolded circle with a line down the middle to represent a parent The number on the left of the line will indicate the primary network address and the number on the right will indicate the corresponding secondary network address DOU Figure 12 Parent Assignments for Example System Note that with these parent assignments the gateway will now respond to the NCU on behalf of the four Modbus devices and it will do so at Metasys addresses 1 2 3 and 4 From this simple example some observations can be made e The gateway will consume as much of the primary network address space as there are parents assigned within it In this example the gateway has 4 parents and therefore takes up 4 Metasys a
37. ed and continuously monitored when points are defined for that drive No drive configuration needs to be performed to connect the XLTR 100 to the drives Just plug it in it s that simple Network Timeout Action A configurable network timeout function can be programmed that allows each internally defined point to have its own unique fail safe condition in the event of a primary network interruption Indicators 2 green LEDs exist on each of the Toshiba ASD ports and on the MMI port connector Refer to section 9 for more detailed information about the LED indicators and their meanings MMI Port Connector RS232 level Use the DB9 to RJ45 MMI cable supplied with the XL TR 100 kit to interface with the unit for either console based configuration point file upload download or flash firmware downloading Field Upgradeable As new firmware becomes available the XLTR 100 unit can be upgraded in the field by the end user Refer to section 15 for more information Versatile 3 Way DIN Rail Mounting System The unit s enclosure is provided with a mounting clip attached to the rear of the unit This clip allows the unit to be mounted 3 different ways e For DIN rail mounting snap the mounting clip onto a standard DIN rail and then snap the unit enclosure onto the clip s retaining tabs This allows easy removal or repositioning of the unit on the DIN rail during wiring e For panel mounting the mounting clip can be bolted directly
38. eir names parent points from hereon referred to simply as parents define the upper most level of mapping information and child points hereon referred to individually as child or collectively as children exist as sub elements of parent points inheriting the parent s attributes while simultaneously adding additional mapping information Parents can have any number of children assigned to them limited only by the maximum number of points available 100 total In certain instances such as with a Modbus RTU primary protocol it is also possible to have parents that do not have any children assigned to them Although the details may vary among different Network Gateway Series devices the conceptual relationship for the XL TR 100 is detailed in Figure 10 Parent 1 Parent 2 422 Parent Figure 10 Parent Child Relationship 24 44 12 1 Parents Parents map a primary network address device to a secondary network address device This can perhaps best be demonstrated by use of an example Say for instance that a Metasys N2 Network Control Unit NCU would like to gain access to four Modbus RTU devices The Modbus devices have been pre assigned the addresses 5 7 9 and 11 This system is represented in Figure 11 Primary Network Secondary Network Address Address 5 7 Address Address 9 11 Modbus Devices Figure 11 Example System In order to allow the NCU to access the Modbus devices w
39. ept The XLTR 100 is a member of the ICC Network Gateway Series product family Members of this family are designed to provide a uniform interface configuration and application experience This commonality reduces the user s learning curve reducing commissioning time while simplifying support The heart of the Network Gateway Series concept is an element called the point database refer to Figure 1 The point database is entirely user configurable and provides the end to end mapping information that allows primary network requests to be routed to the correct locations on the secondary network while at the same time ensuring that the content of the request will be understood once it gets there Additionally the point database provides the added benefit of data mirroring whereby current copies of point values secondary network data objects are maintained locally within the gateway itself This greatly reduces the primary network s request to response latency time as requests read or write can be entirely serviced locally thereby eliminating the time required to execute a secondary network transaction When properly configured the gateway will become essentially transparent on the networks and the primary network master can engage in a seamless dialogue with one or more secondary network devices This can all be accomplished without regard to the characteristics physical layer or protocol of the primary or secondary network
40. es not receive any Metasys packets for a specified period of time causing a network timeout Refer to section 12 3 for more information about configuring network timeout parameters 55 44 14 2 Secondary Networks 14 2 1 Modbus RTU e The gateway acts as a Modbus RTU master via the secondary RS 485 port Supported Modbus functions are indicated in Table 3 Table 3 Supported Modbus Master Functions Function Code Function Read multiple registers 16 Write multiple registers e The slave response timeout is fixed at 3s e Network characteristics selections o Baud rate 2400 4800 9600 19200 38400 bps Parity odd even none 1 stop bit none 2 stop bits e Any defined children will be continuously read by the gateway for data mirroring When allowed by the primary network protocol primary network requests that target registers not declared as children will generate secondary network traffic only on demand e Modbus is not available as the secondary network if it has already been selected as the primary network Console holding register number entry radix is decimal e g 10 1040 56 44 14 2 2 Toshiba Protocol The gateway acts as a Toshiba ASD master via the dedicated common serial port connections All Toshiba ASDs that include a common serial port are supported Network characteristics selections no configuration is necessary as the gateway automatically adapts to the
41. et 1 1 1 1 1 1 4 D D 4 4 4 41 4 69 le j 4 p 1 1 1 1 1 1 1 L F 1 1 1 ee 17771 i mpm 70 icc INDUSTRIAL CONTROL COMMUNICATIONS INC 2204 Timberloch Place Suite 250 The Woodlands TX USA 77380 1049 Tel 281 292 0555 Fax 281 292 0564 World Wide Web http www iccdesigns com Printed in U S A
42. exit at any menu prompt to reboot the gateway and startup the communication tasks Note that whenever you modify the point database and are ready to restart the gateway you must save the database to the file system prior to restarting or your changes will be lost The console will automatically warn you that any unsaved changes will be lost and prompt you for confirmation every time you exit even if the database had not been modified If the database was unchanged then no saving is required 49 44 14 Network Specific Information This section will discuss topics that are specific to each of the available primary and secondary network selections 14 1 Primary Networks 14 1 4 Modbus RTU e The gateway acts as a Modbus RTU slave Supported Modbus functions are indicated in Table 2 Table 2 Supported Modbus Slave Functions Function Code Function 1 Read coils 3 Read multiple registers 5 Write 6 Write single register 15 Force multiple coils 16 Write multiple registers Broadcast for functions 5 6 15 16 is supported e Required Child Point Information o Holding register 4X reference e Point diagram nomenclature as indicated in Figure 35 Holding Register Figure 35 Modbus Slave Point Diagram Nomenclature e Network characteristics selections o Baud rate 2400 4800 9600 19200 38400 bps o Parity odd even none 1 stop bit none 2 stop bits e Console holding register nu
43. first time the RFU utility is run on a computer several configuration items need to be confirmed These configuration items are retained in the computer s registry from that point on so reconfiguration is not required unless certain parameters such as which serial port to use on the computer are changed The two configuration items that need to be confirmed are the communications and bootstrap loaders path First select the Setup Communications menu item refer to Figure 43 Mi Rabbit Field Utility 2 40 BHA File Setup Help Communications File Locations Figure 43 RFU Main Screen 64 44 The Communications Options window shown Figure 44 then appears Confirm that the settings are as shown with the possible exception of the Comm Port settings which depends on the COM port you are using Click OK when complete Note It is possible that certain computers may have difficulty communicating at a sustained 115kbaud rate which may result in communication errors during firmware downloading If this occurs try setting the baud rate parameter shown in Figure 44 to a lower value Communications Options Options f Use Connection Serial Options f Use Serial Connection Baud Rate 115200 Comm Port E Enable Processor Detection Use USE to Converter Cancel Help Figure 44 Communications Options Window Next select the Setup
44. gested that users check this Internet site prior to installation and then periodically afterwards to determine if new support packages have been released and are available to upgrade their units 15 1 Requirements Besides the new firmware file firmware updates require a PC with a Windows operating system Windows 95 or newer and a serial port the RFU PC application refer to section 15 3 and the MMI cable included with the gateway kit ICC part number 10425 Please be sure to read the firmware release notes and updated user s manual included with the BSP for any important notices behavior precautions or configuration requirements prior to updating your firmware For example upgrading to a new firmware version may affect user defined point files prior to starting an update procedure always back up your point files to a PC for later recovery if necessary 15 2 Connection The gateway ships from the factory with a dust cover installed in the MMI port To minimize contamination of the port s electrical contacts keep this dust cover in place whenever the MMI port is not in use IMPORTANT Note that the gateway will not be operating its system control and communication tasks while its internal firmware is being updated Therefore be sure to shut down the system to a known safe state prior to initiating the firmware update procedure Connect the RJ45 end of the MMI cable to the MMI port and connect the other end to the computer s se
45. h that it is located well away from any electrical noise sources such as ASD input power or motor wiring Also take care to route the cable away from any sharp edges or positions where it may be pinched Repeat step 2 above to connect the secondary network to the Secondary RS 485 terminal block 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 J 11 Connect the power supply to the gateway s Power jack 44 4 2 Toshiba ASD Common Serial Secondary Network 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 511 on the front of the drive enclosure under a small snap on cover A7 59 on the right hand side of the drive enclosure under 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 man
46. ints Visually check that the crimp points are not scarred by overheating 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 20 44 8 Storage and Warranty 8 1 Storage Observe the following points when the gateway is not used immediately after purchase or when it is not used for an extended period of time e 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 e When not using the unit for an extended period of time apply power at least once every two years and confirm that it still functions properly 8 2 Warranty The gateway is covered under warranty by ICC Inc for a period of 12 months from the date of installation but not to exceed 18 months from the date of shipment from the factory For further warranty or service information please contact Industrial Control Communications Inc or your local distributor 21 44 9 LED Indicators The gateway contains several different LED indicators each of whi
47. irect Hyper Terminal File Edit View Call Transfer Help 9 Main Menu gt Kmodem Point File Enter the Kmodem mode you will use CRC 1 Enter Upload Download Upload file to the KLTR 100 gt 1 Download a file from the ALTR 100 gt gt Cancel 31 The ALTR 100 is ready to receive your file via Mmodem Upload the file now CCCCCCCCC Connected 6 03 17 ANSIW 38400 8 1 Figure 33 Uploading Point File In HyperTerminal the send function can be selected by the 0 icon in the toolbar This will bring up a dialog box Figure 34 that allows you to select the source file and the transfer protocol Xmodem Upon entering the information and selecting Send the upload transfer will begin This will only take several seconds to complete and at the conclusion the console will indicate the status of the transfer and if successful will prompt for a file system location in which to store the received file The console does not prompt for a filename as the point file is internally watermarked with the name the file was given when it was originally created and stored in the file system 48 Send File Folder C temp Filename CA temp assy Line 3 Point File Protocol Figure 34 HyperTerminal Send File Dialog Box 13 5 6 XLTR 100 Information Main menu selection number 6 displays the unit s application firmware version information 13 5 7 Exit amp Restart Type
48. ld point is performed and the write data is out of range of the corresponding secondary network object no Modbus exception will be immediately returned However the child point will always reflect the secondary network status and object value In other words if such an out of range write is performed the unsuccessful secondary side write can be observed by reading the current unchanged value of the child point during a subsequent Modbus transaction e The gateway be configured to perform a specific set of actions for each point when Modbus communications are lost Modbus communications are said to be lost when the gateway does not receive any Modbus packets for a specified period of time causing a network timeout Refer to section 12 3 for more information about configuring network timeout parameters Coil Mappings The gateway provides read write support for Modbus coils Accessing coils does not reference any new physical data coils are simply indexes into various bits of Modbus holding registers What this means is that when a coil is accessed that coil is resolved by the gateway into a specific holding register and a specific bit within that holding register The pattern of coil to register bit relationships can be described as follows Coils 1 16 map to holding register 1 bitO bit15 080 158 bit152MSB Coils 17 32 map to holding register 82 bitO bit15 and so on 51 44 Arithmetically the coil
49. mber entry radix is decimal e g 10 1010 50 lec e Children are optional because the Modbus protocol does not specify any response time requirements targeted registers do not need to be configured as children which provide data mirroring If a targeted holding register is found to not exist as a defined child point for a specific parent then the request will be passed on to the secondary network for servicing While providing the benefits of requiring very little configuration only parent points need to be defined and allowing access to the full object address range on secondary network devices this technique does incur the penalty of increased latency as affected requests must be passed on to the secondary network for processing and subsequent response e Configuration tip Improved primary network utilization may be obtained by appropriately grouping disjoint secondary network objects into contiguous blocks of children contiguous holding register assignments In this way the read multiple registers and write multiple registers functions can be used to perform transfers of larger blocks of registers using fewer Modbus transactions compared to a situation where the read write registers were arranged in an alternating or scattered fashion Because the transaction is handled locally within the gateway write data checking is not available for defined children For example if a write to a register or coil defined by a chi
50. mber to the right of the gt symbol along with any required data fields at the console prompt In Figure 19 for example entering the menu selection number 1 without the quotation marks will bring up the View Edit Points submenu Throughout this manual example console entry strings will be provided enclosed in quotation marks to delineate them from the description text whenever actually entering the console strings however do not include the quotation marks When additional data fields are required with a data entry command they will be indicated by square brackets after the menu selection number data entry commands and data fields must be separated by spaces Because data entry commands and data fields are delineated by spaces they are therefore not allowed within data fields such as name strings In these cases it is usually convenient to use an underscore in place of a space For example attempting to enter a filename as My test file would result in an error but My test file would be perfectly acceptable 36 44 13 5 1 View Edit Points Main menu selection number 1 displays a screen which shows a summary of the current point configuration see Figure 20 This screen only displays the parent point address mapping information in order to access any child point information menu selection number 1 Edit a Parent must be entered with the additional argument of the targeted parent point s primar
51. nt 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 44 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 10 50 C 14 122 F Storage 40 85 C 40 185 F e Avoid installation locations that may be subjected to large shocks or vibrations e Avoid installation locations that may be subjected to rapid changes in temperature 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 e Route all communication cables separate from high voltage or noise emitting cabling such as ASD input output power wiring ASD Connections 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 e avoid misoperati
52. o 0 The secondary network data s least significant bit LSB is bit 0 and the most significant bit MSB 1 bit 15 The BI point diagram nomenclature is as indicated in Figure 38 In the example indicated by this figure BI1 s current state will be 1 whenever bit 7 of the secondary network data is 1 e g 0x0080 and will be 0 at all other times NPA Network Point Address 1 2 NPT Network Point Type Figure 38 2 BI Object Point Diagram Nomenclature e Binary output BO points are used for setting and monitoring discrete control and configuration items A BO value can be modified by issuing an override command Issuing a release command will not cause the BO to automatically return to its pre override value nor will the BO return to its pre override value after a certain time period of no communication An value and an OFF value both 16 bit numbers are associated with the object When the BO s current state is set to 1 by the NCU then the value is written to the child s secondary network data object and when the BO s current state is set to 0 by the NCU then the OFF value is written to the child s secondary network data object In this way complex or multi function secondary network commands can be issued in response to a simple Metasys BO ON OFF override command The BO point diagram nomenclature is as indicated in Figure 45
53. on do not connect any gateway terminals to either the ASD s E GND terminals the motor or to any other power ground e When making common serial connections between the gateway and Toshiba ASDs do not use cables that exceed 5 meters in length e For further drive specific precaution safety and installation information please refer to the appropriate documentation supplied with your drive Internal ASD EEPROMs have 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 e 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 44 TABLE CONTENTS 1 The Network Gateway Series Concept 6 2 Mechanical 7 2 1 ENCIOSUTE 7 2 2 Mounting esiste 9 2 3 9 32 Feature SUMIMANY 10 4 Installing the Interface eese 13 4 1 RS 485 Secondary
54. osen using a different criteria grouping according to device application or function for example 26 44 Now that we thoroughly understand the role of parents the gateway configuration let s move on to the only slightly more diverse topic of children 27 44 12 2 Children While parents provide an address to address mapping function children provide a lower level object to object mapping function The definition of what constitutes an object can vary depending on the protocols and devices involved For example an object on the Metasys network can be a Binary Output Binary Input BI Analog Output AO or Analog Input Al On the other hand an object on a Modbus network is simply a Modbus holding register and on a Toshiba network is a drive parameter configuration parameters control parameters and status parameters are all handled the same by the gateway Therefore a child could map an AO to a register when the primary network is Metasys N2 and the secondary network is Modbus or it could map a register to a drive parameter when the primary network is Modbus and the secondary network is Toshiba protocol The child is therefore responsible for migrating a specific piece of data from a device on one network to a device on another network The specific object indices register number Bl number etc are completely user configurable within the child point configuration The specific configurable items asso
55. r configuration switches located on the bottom side of the gateway Currently switches 1 3 are reserved and switch 4 is used during flash firmware reprogramming of the gateway refer to section 15 11 Internal Battery The XLTR 100 gateway has an internal coin cell type battery that is used to backup the file system when the gateway is unpowered This battery is designed to last the lifetime of the product under normal use However if the gateway is left unpowered for several years the battery may become exhausted For this reason always be certain to download any customized point files to a PC so that they will be available for uploading again if the battery fails and requires replacement If the battery becomes discharged contact ICC for assistance in obtaining a replacement Alternatively it can be replaced by the user by removing all power sources from the gateway opening the case carefully popping out the discharged battery and replacing it with a Panasonic BR2330 or equivalent component 23 44 12 Point Configuration As mentioned in section 1 the Network Gateway Series concept revolves around a central point database containing various individual points A point is simply an object that defines some sort of primary to secondary network mapping information There are two different types of points e Parent points e Child points The relationship between these two point types is as suggested by th
56. register 3 bit 1 Note that this coil to register bit relationship holds true regardless of how or even if holding register 3 is defined If holding register 3 is defined as a point in the point database then this coil access will be entirely internal to the unit If holding register 3 is not defined as a point in the point database however then an on demand secondary network transaction will take place requesting data object number 3 and returning the value of bit 1 of that data object Either way coil 34 will always access holding register 3 bit 1 52 44 14 1 2 Metasys 2 The gateway acts as a Johnson Controls Metasys N2 slave and supports N2 analog input analog output binary input and binary output object types Analog input Al objects are used for monitoring analog status items Al objects support low alarm limits low warning limits high warning limits high alarm limits and differential values Change of state COS alarm and warning functions can also be enabled An Al object will accept an override command but will not change its actual value or indicate override active A multiplier value is associated with the object and is multiplied to the child s secondary network data to produce the floating point AI value sent to the Al value secondary side data value X multiplier The Al point diagram nomenclature is as indicated in Figure Network Point Address 1 2
57. rial port Move CONFIG switch 4 to the ON down position this will place the gateway into the firmware download mode Whenever CONFIG switch Z4 is the gateway can only download firmware to its flash memory all other application functions such as communications console access etc will be disabled 63 44 15 3 Using the RFU Utility Support for downloading new application firmware to the gateway is provided by the free Rabbit Field Utility RFU which is a 32 bit application that runs on Microsoft Windows platforms The RFU utility can be downloaded from ICC s home page at hitp www iccdesigns com When downloading a new gateway application BSP always confirm that you also have the latest version of RFU as new BIN firmware files contained in BSPs may require functionality found only in the most recent RFU versions for successful downloading The remainder of this section will detail the RFU utility configuration and firmware download procedures 15 3 1 Required Files When first downloaded the RFU utility files are compressed into one self extracting EXE distribution file Create a folder Such as c RFU place the distribution file in this folder and then execute it This will extract the compressed files into that same folder The distribution file is then unneeded and can be deleted if desired To run the RFU utility double click on the RFU EXE file icon 15 3 2 First Time Configuration The
58. ruction manual describes the device specifications wiring methods maintenance procedures supported functions usage methods and firmware update procedures for the XL TR 100 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 e XLTR 100 interface in DIN rail mountable case 2meter DB9 RJ45 MMI port cable part number 10425 e This manual METASYS 18 A REGISTERED TRADEMARK OF JOHNSON CONTROLS INC 44 100 5 485 Multiprotocol Network Gateway User s Manual Part Number 10484 2 100 000 Printed in U S A 02002 2004 Industrial Control Communications Inc All rights reserved 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 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 prese
59. s children if any must be added by using the Edit a Parent menu selection refer to section 13 5 1 1 Note that parent addresses must be unique if an attempt is made to enter a primary or secondary network address that has already been defined the console will return an error 41 1 Direct Hyper Terminal File Edit View Call Transfer Help Main Menu gt Edit Points Primary Protocol Metasys N2 Secondary Protocol Modbus RTU N2 Address RIU Address 1 1 9 10 8 27 44 16 Edit Parent a New Parent N2 fiddress N2 fiddress 1 2551 IRTU fiddress 1 2471 N2 fiddress Metasys N2 Setup Modbus RTU Setup Preuious Menu 2249 1 2 9 4 9 6 K Connected 5 29 27 ANSIW 38400 8 1 Figure 25 Add a New Parent 13 5 1 3 Delete a Parent Entering menu selection number 3 with the additional argument of a parent s primary network address will delete that parent and all of its children 13 5 1 4 More Parents The parents table displays the mapping information for 4 parents at a time If more than 4 parents are available in the current configuration menu selection number 4 will display the next 4 parents in the list When all parents have been displayed entering menu selection number 4 will roll back around to the first 4 parents again 73 5 1 5 Primary Network Setup Menu selection number 5 displays a submenu that provides a means to configure the characteristics of the selected primary net
60. s equally to the primary as well as secondary networks Signal Ground Shield Figure 7 RS 485 Terminal Block Connections 18 44 6 Environmental Specifications Indoors less than 1000m above sea level do not Operating Environment expose to direct sunlight or corrosive explosive gasses Operating Temperature 10 50 14 122 F Storage Temperature 40 85 C 40 185 F Relative Humidity 20 90 without condensation 5 9m s 0 6G or less 10 55Hz Non isolated referenced to power source ground Cooling Method Self cooled 44 7 Maintenance and Inspection Preventive maintenance and inspection is required to maintain the gateway in its optimal condition and to ensure a long operational lifetime Depending on usage and operating conditions perform a periodic inspection once every three to six months Before starting inspections disconnect all power sources with Toshiba ASD connections turn off all power supplies to connected drives and wait at least five minutes after each drive s CHARGE lamp has gone out Inspection Points Check that the dust covers for all unused RJ45 ports are seated firmly in their connectors 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 po
61. so note that console commands are not case sensitive COM1 Direct HyperTerminal File Edit Call Transfer Help XLTR 100 Console Version 2 0 gt menu ENE OR RHA i This serial console interface is used to configure the 100 Starting the XLTR 100 configuration interface will cause the 100 to suspend all communications tasks Please read the 100 user s manual before attempting configuration to continue gt Connected 5 26 29 ANSIW 38400 8 N 1 Figure 18 Starting the Console 35 44 13 5 The main menu is shown in Figure 19 All gateway configuration is performed by drilling down into progressively lower level menus COM1 Direct HyperTerminal File Edit View Call Transfer Help This serial console interface is used to configure the 100 Starting the XLTR 100 configuration interface will cause the XLTR 100 to suspend all communications tasks 7 Please read the MLTR 100 user s manual before attempting configuration 7777 7 7 7 7 7 7 7 7 7 to continue gt ok Main Menu Xmodem Point File ALTR 188 Information Exit amp Restart 2 Connected 5 30 06 ANSIW 38400 8 N 1 Figure 19 Console Main Menu All navigation and data entry commands are input by simply entering the menu selection nu
62. so take care to route the cable away from any sharp edges or positions where it may be pinched an auxiliary power supply is going to be used connect it to the gateway s Power jack Take a moment to verify that the gateway and all primary and secondary network cables have sufficient clearance from drives motors or power carrying electrical wiring 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 1 and 2 to remove all power from the drives Then verify all connections Contact ICC or your local Toshiba representative for assistance if the problem persists 44 5 RS 485 Electrical Interface In order to ensure appropriate network conditions signal voltage levels etc some knowledge of the gateway s RS 485 network interface circuitry is required Refer to Figure 6 for a simplified network schematic of both the primary and secondary RS 485 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 A TB 1 B TB 2 SG TB 3 Figure 6 RS 485 Interface Circuitry Schematic Figure 7 details the specific network connections to the RS 485 terminal block This connection scheme applie
63. t to 9999 Parameter 124 341 CR LF selection Must be set to 1 CR only 60 44 14 2 4 Sullair Supervisor Protocol e The gateway acts as a Sullair Supervisor Protocol network monitor via the secondary RS 485 port It can automatically adapt to the Supervisor network configuration sequencing or non sequencing slave mode e Any numerically addressed parameter defined by the Supervisor protocol is directly accessible machine type parameter 1 etc However some Supervisor data objects are not natively numerically addressed For these data objects the additional parameter numbers indicated in Table 5 have been assigned Table 5 Additional Supervisor Parameter Assignments Parameter Number Item Note Source 100 Capacity 224 101 102 Runhors 0 E stop 1 remote stop 2 manual stop 3 standby 6 103 Run status 4 starting 5 load 6 unload trim 8 full load 1 continuous 105 L x _ 07 0 l 106 pq 107 108 40127 109 1 110 120274 111 2 1 2 112 4 113 ___ gt oo 114 E 115 Analog shutdown 116 Relayoupus 117 Digital shutdown 118 Digital inputs 119 Runtime 120 loadtime 1 online sequencing oo g 127 Faulted 0 not faulted 2 o5 1 faulted 61 44 defined children will be continuously read by the gateway for data mirroring Additionally info status messages
64. the Kmodem mode you will use CRC gt 1 Checksum gt 2 Cancel gt gt 1 Enter Upload Download Upload a file to the KLTR 100 gt 1 Download a file from the HLTR 100 gt 2 Cancel gt a 2 Enter the file to download fissy Line 6 2 to 2050 Connected 6 00 52 ANSIW 38400 8 N 1 Figure 30 Downloading a Point File Receive File Place received file in the following folder C temp Browse Use receiving protocol modem ka Close Cancel Figure 31 HyperTerminal Receive File Dialog Box Receive Filename modem never sends a filename so you must specify a filename for staring the received file Folder Filename Assy Line Point File Figure 32 HyperTerminal Receive Filename Dialog Box 47 44 As soon as the filename is entered and selected the download transfer will begin This will only take several seconds to complete and at the conclusion the console will indicate the status of the transfer and return to the main menu Uploading a file from the PC to the gateway is similar in many ways to downloading Figure 33 shows an example of initiating a file upload Once the console indicates that the gateway is ready to receive the file you have 30 seconds in which to initiate the send function of your terminal emulation program before the gateway will timeout the transaction and return to the main menu prompt COM1 D
65. ual supplied with your drive Note that the common serial communication parameters of each drive are handled independently by the gateway which means that different drive families may be connected to different channels of the unit in any combination and that the drives connected to each channel may simultaneously communicate to the unit at completely different baud rates parity settings etc Drives can be connected to the gateway on any ASD channel in any order or combination When more than one drive is connected to the unit or if the optional auxiliary power supply is used the gateway will draw its control power from the source with the highest power supply voltage Installation of the gateway should only be performed by a qualified technician familiar with the maintenance and operation of the connected drives To install the gateway complete the steps outlined in the following sections related to your specific drive 4 2 1 Installation for G7 ASDs 1 N CAUTION Verify that all input power sources to the drives to be connected have been turned OFF and are locked and tagged out 2 DANGER Wait at least 5 minutes for the drive s electrolytic capacitors to discharge before proceeding to the next step Do not touch any internal parts with power applied to the drive or for at least 5 minutes after power to the drive has been removed A hazard exists temporarily for electrical shock even if the source power has been removed
66. ustom cable For simplicity a standard 8 conductor Ethernet patch cable can be used as a starting point There are two standard color schemes for the wire pairs in such cables as defined by the Electronic Industry Association Telecommunications Industry Association EIA TIA These two standards are called T 568B and 568 refer to Figure 41 The most common color scheme is T 568B and will therefore be the one used for this example connection If starting with a cable wired according to the 568 specification just interchange the colors to achieve the same pin connections Connect as shown in Figure 42 58 44 568 568 12345678 12345678 RJ 45 Plug GB B G Br Gi G O B B O Br Br Figure 41 EIA TIA Wiring Standards 568 12345678 1 jd 070 GI B B G Bal Br RDA SDA SDB RDB A B Signal TB 1 TB 2 Ground TB 3 Figure 42 PU Port Connections e The slave response timeout is fixed at 2s e Network characteristics selections o Baud rate 300 600 1200 2400 4800 9600 19200 bps o Parity odd even none 1 stop bit none 2 stop bits e Console parameter number entry radix is decimal e g 10 1040 e Anynumerically addressed parameter defined by the Mitsubishi protocol reference manual is directly accessible base frequency parameter 3 59 44 etc However some ASD data objects do not parameter numbers assigned by Mitsubishi For these
67. wable object ranges vary depending on the currently active networks The child type varies depending on the primary network selected For example with a Modbus RTU primary network the child type will always be for register If a Metasys N2 primary network is selected however then the child type could be AO BO Al or 1 Direct Hyper Terminal File Edit View Call Transfer Help 11 Hain Menu gt Edit Points gt Edit Parent ype number number RTU Address TU Address 1 2471 ASD Address ASD SD Address ASD1 85021 Edit a Child EG RTU reg num 1 655351 fidd a New Child 01 RTU reg num 1 655351 ASD param 8 FFFF Delete a Child 01 RTU reg num 1 655351 More Children Preuious Menu gt 4 reg 11 14 Connected 2 53 06 38400 8 1 Figure 23 Add New Child 13 5 1 1 5 Delete a Child To delete a child from the configuration enter menu selection number 5 with the additional arguments of the child s type and primary network object number For example Figure 24 shows an example of deleting a child that represents Metasys N2 1 The semantics of the menu prompt and allowable object ranges vary depending on the currently active networks The child type varies depending on the primary network selected For example with a Modbus RTU primary network the child type will always be for register If a Metasys N2 primary network is
68. work such as baud rate and parity Refer to Figure 26 for an example Note that not all primary networks are user configurable The specific menu label and subsequent available submenu options depend on the currently active primary network Along with the network characteristics this submenu allows for setting the network timeout time For more information on the network timeout configuration refer to section 12 3 42 44 COM1 Direct Hyper Terminal File Edit View Transfer Help gt 5 Main Menu gt Edit Points gt Edit Modbus RTU 1 2400 2 4800 3 9600 4 19200 5 398400 11 044 2 Even 3 None 1 stop 4 None 2 stop 0 500 seconds Baud Rate 9600 gt Parity 1 stop gt 2 Timeout Time 9 3 Preuious Menu gt n 2 0 59 22 ANSIW 38400 8 N 1 Figure 26 Example Primary Network Setup 73 5 1 6 Secondary Network Setup Menu selection number 6 displays a submenu that provides a means to configure the characteristics of the selected secondary network such as baud rate and parity Note that not all secondary networks are user configurable The specific menu label and subsequent available submenu options depend on the currently active secondary network 13 5 2 Save Points Main menu selection number 2 allows the current gateway configuration to be saved to one of the three available file locations in the gateway s file system It is important to reiterate that whenever
69. y network address The top half of the screen contains the parents table which lists the primary and secondary network addresses of each parent The bottom half of the screen contains the menu options for editing the parent points and network characteristics COM1 Direct HyperTerminal File Edit Call Transfer Help 1 Main Menu Edit Points Primary Protocol Modbus RTU Secondary Protocol Toshiba RSD Address ASD Address 1 8501 2 1502 Edit a Parent fidd a New Parent Delete a Parent TU Address 3 More Parents 6 K R RTU Address 1 247 ASD Address ASD1 ASD2 RTU Address Modbus RTU Setup Toshiba ASD Setup Previous Menu ELLE Connected 0 16 44 ANSIW 38400 8 N 1 Figure 20 View Edit Points 13 5 1 1 Edita Parent Entering 1 with a parent point s primary network address such as 1 1 as shown at the bottom of Figure 20 at the View Edit Points submenu will display and allow editing of the parent s mapping and child point definition information Refer to Figure 21 for an example Although the number of menu selections in this submenu will remain consistent the semantics of the menu titles and argument names will vary slightly depending on the currently defined networks When editing a parent the top half of the screen contains the children table which lists the child types relevant only for those networks such as Metasys N2 which allow different types of chil

XLTR-100 V2.100 User`s Manual

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