PowerTALK103 User'S Manual

PowerTALK 103 User'S Manual

Configuration, testing, deployment and manual for PowerTALK 103 communications equipment.

Document Control Information

Document Release Date

1 November 1998

Document Release Number

2.0

Firmware Release

1.00

Contact / Support

powertalk@cocoon-creations.com

Foreword
Introduction
PowerTALK 103 Concept and operation
PowerTALK 103 Specification
Connecting PowerTALKs in a RS-485 network:
Appendix A - Cable connections

The PowerTALK 103 Industrial Unit as seen from below...

Foreword

The PowerTALK product family, available from www.cocoon-creations.com, is a modular set of tools that enables engineers and process controllers to centralise the monitoring and management of proprietary industrial equipment.

COCOON has recognised that there is legacy equi

Introduction

Brief Description

PowerTALK 103 is part of the family of interface converters from Cocoon Creations cc.

PowerTALK 103 is an industrial quality RS-232 to RS-485 converter. For maximum flexibility, two independent RS-232 ports and one RS-485 port are offered. These ports are electrically isolated and functionally connected to each other.

An RS-232 connection is intended to be a one-to-one link. No more than two devices can be accommodated on such an RS-232 link.

An RS-485 system allows effective resource sharing. RS-485 is the electrical interface used by many manufacturers to transport different higher level protocols and shows the versatility of the RS-485 electrical standard.

Application

The PowerTALK 103 unit can be used to transmit data from a 3 wire RS-232 asynchronous interface to a 2 wire RS-485 interface. Typical applications are protection relays, metering instruments, protocol converters, multi-drop converters, RS-485 repeaters, microcontrollers, PLC’s, etc.

Ordering options

Power Supply Input: 12VDC
Network Connection: EIA RS-485
Serial Connectors: 2 off 25-pin D-type male serial connectors,
Gate mode: Optional
Terminals: 36 Phoenix type screw terminals for 0.14 to 1.5 mm² wire

The PowerTALK unit is marked on the front with the model number, and on the back with the network address, if applicable.

The following options may be specified for PowerTALK 103 at time of order. At COCOON’s discretion more options than those stated below may be justified.

Order number Description Short name

PT1030-012D-100 12 Vdc, 2x 25 pin connectors, no gate "PT1030"
PT1030-012D-110 12 Vdc, 2x 25 pin connectors, with gate "PT1030G"
PT1030-012D-101 12 Vdc, 2x 25 pin connectors, no gate & rail mount base
PT1030-012D-111 12 Vdc, 2x 25 pin connectors, with gate & rail mount base
PT1030-0000 -199 Rail mount base, for using PowerTALK on DIN and G rail

All models can be re-programmed by the suppliers for firmware version upgrades.

PowerTALK 103 Concept and operation

Block diagram

Depending on the actual mode setting of the PowerTALK 103 device, the unit essentially moves data from one port to another on the same device, performing effective interface conversion.

The block diagram of the PowerTALK 103 unit clearly shows that the RS-232 ports are electrically isolated from each other and from the RS-485 port.
The micro-processor (¼P) performs the integrating and gate functions between the ports.
The RS-485 bus driver is controlled by the timer circuitry in T.

RS-232 Port configuration

An RS-232 port has a set of 2 jumpers pre-connected to the PowerTALK 103 screw terminals, i.e. 32-33, 31-34, 19-22 and 20-21. These jumpers are to re-configure the Tx/Rx orientation.

If reversed, i.e. 19-21 and 20-22, the effective Rx and Tx pins on the DB-25 connector has functionally changed around. This swapping is needed where a PowerTALK 103 needs to be connected to an existing serial cable with its Tx/Rx requirement swapped.

Master port description

A mechanism is implemented by which the user can configure the data flow in PowerTALK 103. transmissions are based on differential signals, i.e. both A and B invert their relative polarities for a bit change. In the case of RS-485 the A and B signals have a third high impedance state which is used when no signal is transmitted. This keeps the bus open for other transmitters to transmit at will.

Since PowerTALK 103 does not support the use of hardware flow control signals to switch the transmitters off after a byte has been transmitted, it uses another method to limit the transmition time on the bus: The unit can be configured to have either a 9600 or 1200 baud delay time, i.e. the transmitters are switched off for 10/9600 seconds or for 10/1200 seconds after the last low bit is sent through.

This ensures that the transmitters are on for at least one word length at 10 bits (1 start + 8 data + 1 stop bits) after the start of any word transmitted. It also means that a device cannot answer the caller within 1 byte’s transmission time after completion of the calling message.

RS-485 Over-Voltage suppression

RS 485 output stage, showing over voltage suppression devices in circuit

Type test surge over-voltage waveform as suggested by IEC 1000-4-5

Surge over voltage type test measurements, showing the amount of energy dissipated by the RS-485 output stages in PowerTALK 103

Information on this page obtained from Texas Instruments

PowerTALK 103 Specification

Type:

Intelligent isolated RS-485 to RS-232 converter

Features:

Dual three-wire RS-232 (ports A & C)
Single two-wire RS-485 (port B)
2.5kV 50Hz Ac isolation between ports
RS-232 ports are port powered, with external power terminals
Drives 64 other PowerTALK units

RS-485 bus control

Selectable 1200 or 9600 baud

Configuration

Selectable Master B or Master C

Design

Basic housing: 120 x 53 x 17 (L x W x H) (mm)
Housing incl. rail plate: 130 x 65 x 19 (L x W x H) (mm)
Optional flat mounting plate, for DIN rail and G rail.
Direct fit under glass cover of Siemens protection relays.
Led’s facing connector direction, visible if rail mounted.

Power Supply:

RS-232 ports powered by Tx, Rx, DTR, DSR, Rts, CTS and pin 9 for custom powering solutions
RS-232 ports have external power terminals
RS-485 port has external power terminals

Protocol

All speeds and options up to 9600 baud

RS-232 ports

Three wire connection: only Tx and Rx signals are supported
Optically isolated RS-232 Rx circuit port powered
Passive type optically isolated Tx circuit port powered
The 1030 model has two pre-configured 25 pin male DB-25 connectors mounted, with the PowerTALK Tx signal on pin 2, and Rx on pin 3

RS-485 port

Two wire half duplex mode supported.

"A" terminals 26

Port A: pin 2/25

Port A: pin 3/25

Port A input

Port A output

Port A + supply

Port A – supply

Port A gnd

N/C

Port C gnd

Port C: pin 2/25

Port C: pin 3/25

Port C input

Port C output

Port C + supply

Port C – supply

Port B: RS-485 A (29) +

Port B: RS-485 A +

Port B: RS-485 B (28) -

Port B: RS-485 B -

Port B: +12V

Port B: 0V

1200(+5V) / 9600(0V)

Reserved

+5V

Enable 1 (+5V) / Disable (0V)

Enable 2 (+5V) / Disable (0V)

MasterB (+5V) / MasterC (0V)

Reserved

Typical connection diagram for PT1030

Power Supplies

+V: RS-485 supply +8V to +15V Dc

+, -, 0: External supply for RS-232 input stage, see this link...

B: Baud RS-485 control selection

1200 baud (+5V) terminals 10-13

9600 baud (0V) terminals 10-9

E: Enable gate

Enable (+5V) terminals 13-14-15

Master

Port B (RS-485) Master, term. 16-13

Port C (RS-232) Master, term. 16-10

*P Power supply shortcuts

The RS-485 supply could be used powering port A or C.
Isolation to port B will be sacrificed.

PowerTALK 103 Led indications

Led Layout

A
B
C

G
F
H

Port A: RS-232
Port status
Transmit
Receive

Port C: RS-232
Transmit
Receive
Port status

Port B: RS-485

Receive from bus
Transmit onto bus

Configuration

D
E

Led Indications descriptions

A,H

Port status

Green/red

Green for idle (incoming) Tx signal. See table below.

This Led should not be red for the idle connected condition. This would indicate incorrect Tx/Rx connection. With a single supply, increasing voltage on V+ will fade the green. Adding the negative of a double supply, increasing

Port Rx

Red

Confirming output of the m P to the output isolation stage, indicating a signal into the RS232 stage.

Port B Rx

Red

Confirming output from the line driver into the m P, indicating a signal received by RS-485 drivers.

Port B Tx

Red

Confirming the RS485 bus to be enabled, and the m P sending a signal to the RS-485 driver stage.

Port status Led - detail

PT103 power off

To outside - Into Pt

Tx Mark (traffic)

Tx Space
(no traffic)

Rx Mark (traffic)

n.a.

Red

Rx Space (no traffic)

n.a.

Green

PT103 power on

To outside - Into Pt

Tx Mark (traffic)

Tx Space
(no traffic)

Rx Mark (traffic)

n.a.

Red

Rx Space (no traffic)

n.a.

Green

Above table shows that the Led can be used for relevant information during time of no PowerTALK 103 transmission, i.e. when receiving data from externally. See written description in the table in this link.

Connecting PowerTALK 103 to Siemens 7SJ600 relays

PowerTALK 103 may be set to 9600, Enable & MasterB, see this link.

The RS-485 network is connected as follows:

"A" terminals are positive (7SJ60 terminal 29)

"B" terminals are negative (7SJ60 terminal 28)

The RS-232 port A or port C is connected to the PC using a laplink cable, see Appendix A - Cable connections

Connecting PowerTALK 103 to Multilin relays

PowerTALK 103 may be set to 9600, Enable & MasterB, see this link.

The RS-485 network is connected as follows:

"A" terminals are positive

"B" terminals are negative

The RS-232 port A or port C is connected to the PC using a laplink cable, see Appendix A - Cable connections

Connecting PowerTALKs in a RS-485 network:

Typical network topology:

One PowerTALK unit can be connected in Master C mode, with port C connected to the PC. The other PowerTALK units can be connected to devices to Master B mode.

The RS-485 network is powered from the central power supply at the PowerTALK at the PC location, with the other units powered via spare cores in the network cable from remote.

The PC or modem should be connected with a standard Laplink cable and needs no port power supply.

The Siemens relays 7SJ5xx, 7UT5xx, 7SA5xx, etc. can be connected with a special cable, and does not require special arrangements with the port power supply. The 7SJ531 can be connected with a different cable, and needs some type of port power to be connected.

Typical network connection:

Power Supply Considerations

The RS232 ports requires a single or a double power supply. Depending on software and cables, this may be provided by the hosting device or PC.
The RS485 port requires a single supply to power the line drivers, microprocessors and interna Name="_Toc434997483">Testing PowerTALK 103

General test case conditions and procedures:

The following system conditions are suggested, to ensure correct replication of tests mentioned in this application note:
- For Siemens relays: Digsi 3.30 is to be used, with the following interface settings:
  
  Dicomm: Windows95, Soft.
  Interface: 9600, 11bit
- Power supplies to the PowerTALK modules are to be within the specification, and can be set to typical values of 10V Dc each on both the RS-232 ports and the RS-485 Dc supply.
- All relays are to be tested using the most stringent data flow conditions, i.e. uploading configuration and settings to the relays using the Digsi "File to protection" command as well as monitoring real time measured values on the relays using the Digsi "Measurements" command.
Testing a single PowerTALK unit:

Both RS-232 ports on a PowerTALK unit can be tested by connecting the unit in a "through" configuration. The PowerTALK should be in "Master C mode", providing a trivial "through" condition from port A to port C and vice versa, proving operation of the PowerTALK unit only.

The RS-485 network functionality is not used below:

Connection & configuration

PC to 7SJ531
- Digsi is used
- Communication is proven through the PowerTALK unit, from port C to A and vice versa.
- PC connected with Laplink cable
- Relay connected with special cable
PC to 7SJ5xx or other relay
- Digsi is used
- Communication is proven through the PowerTALK unit, from port C to A and vice versa.
- PC connected with Laplink cable
- Relay connected with special cable
PC to PC
- Terminal emulation programs used both sides
- Either one PC, two ports
- or two PCs, one port each
- Communication is proven through the PowerTALK unit, from port C to A and vice versa.
- PC ports both connected with Laplink cables
Detail PC-PC test procedure
1. Connect two (full handshake) Laplink cables to ports A and C on the PowerTALK.
2. Connect one cable to one PC COM port and another to the other PC COM port.
COM ports may be on the same PC, or not. Two PCs may be used. The Port Led indicates port power and port activity:
1. On the PowerTALK unit:
  - Connect 9-10 (9600 baud)
  - Connect 13-14-15 (Enable)
  - Connect 10-16 (Port C Master)
2. Power up PowerTALK using a Dc supply of minimum 8V and maximum 15V.
3. Start a terminal emulation program on both COM ports, using the following settings:
  - no flow control,
  - arbitrary settings such as 9600 8N1
4. Now type using the terminal program connected to Port A.
1. Start HyperTerminal and select direct Link, COM2, 9600 and no flow control
2. The Port Led (large Led next to port connector) will shine green if sufficient voltage is available on incoming Tx line.
3. Type characters into Port A or C, and observe the Port Led flash red. This confirms correct Tx/Rx connection.
4. Type more characters, and confirm the corresponding red Port A/C Rx Led flashes (see Led diagram). This confirms the isolation stage is functional.
Test Port B and the network (Master B, Master B)
1. On the local PowerTALK, confirm Master B selected, terminals 13 and 16 are shorted.
2. On the remote PowerTALK, confirm Master B selected, terminals 13 and 16 are shorted.
3. Type characters into the local Port A or C and confirm the corresponding red Port A/C Rx Led flashes.
4. Also confirm on the local PowerTALK unit the Port B Tx Led flashes.
5. Also confirm on the remote PowerTALK unit the Port B Rx Led flashes.
6. Also confirm on the remote PowerTALK both Ports A and C Tx LEDs flash.
Test Port B and the Network (Master B, Master C)
1. On the local PowerTALK, confirm Master B selected, terminals 13 and 16 are shorted.
2. On the remote PowerTALK, confirm Master C selected, terminals 10 and 16 are shorted.
3. Type characters into the local Port A or C and confirm the corresponding red Port A/C Rx Led flashes.
4. Also confirm on the local PowerTALK unit the Port B Tx Led flashes.
5. Also confirm on the remote PowerTALK unit the Port B Rx Led flashes.
6. Also confirm on the remote PowerTALK only the Port C Tx Led flashes.
Test Port B and the Network (Master C, Master C)
1. On the local PowerTALK, confirm Master C selected, terminals 10 and 16 are shorted.
2. On the remote PowerTALK, confirm Master C selected, terminals 10 and 16 are shorted.
3. Type characters into the local Port C and confirm the corresponding red Port C Rx Led flashes.
4. Also confirm on the local PowerTALK unit the Port B Tx Led flashes.
5. Also confirm on the remote PowerTALK unit the Port B Rx Led flashes.
6. Also confirm on the remote PowerTALK only the Port C Tx Led flashes.
7. Incorrectly remove the PC laplink cable from Port C to Port A on the Local PowerTALK.
8. Type characters into the local Port A and confirm the corresponding red Port A Rx Led flashes.
9. Also confirm on the local PowerTALK unit the Port B Tx Led Does Not flash.
10. Also confirm on the remote PowerTALK unit the Port B Rx Led Does Not flash.
11. Also confirm on the remote PowerTALK unit the Port C Tx Led Does Not flash.
Testing a PowerTALK RS-485 network

Running Digsi 3.30 on the PC, communicating to the 7SJ600 and 7SJ531 relays, with the PC side PowerTALK in "Master C" mode, and the relay side PowerTALK no. 2 in "Master B mode".

Ports A and/or C may be used for relay communications.

PC - RS485 - Relay

Complete PowerTALK systems test

This is the practical networking configuration and can also be used to prove PowerTALK and network functionality, testing RS-232 and RS-485 ports of both PowerTALK units.

Configuration:

PowerTALK 1: Master C

PowerTALK 2: Master B

Variations:
- Add more 7SJ600 relays to the RS-485 network.
- Add more PowerTALK units to allow more relays connected on RS-232.
- Add a local relay to PT1A
- Replace the on board Dc/Dc converter on PT2C with jumpers to the RS-485 supply.
- Replace the on board Dc/Dc converter with an external power supply unit.
- Tx-Rx
  
  Rx-Tx
  
  PC Gnd
  
  1
  PC to Relay #
  "Digsi cable"
  "Straight"
  
  9pF 25pM
  
  3/9-2/25
  
  2/9-3/25
  
  5/9-7/25
  
  2
  PC to 7SJ531
  special
  "Swapped"
  
  9pF 9pM
  
  3/9-2/9
  
  2/9-3/9
  
  5/9-5/9
  
  3
  PC to PowerTALK
  Laplink *
  "Swapped"
  
  9pF 25pF
  
  3/9-3/25
  
  2/9-2/25
  
  5/9-7/25
  
  4/9-6/25
  
  6/9-20/25
  
  7/9-5/25
  
  8/9-4/25
  
  4
  PowerTALK to Relay #
  special
  "Straight"
  
  25pF 25pM
  
  2/25-2/25
  
  3/25-3/25
  
  7/25-7/25
  
  9/9-9/25
  
  5
  PowerTALK to 7SJ531
  See cable 3A
  
  
  
  6
  RS-485 network cable
  Cat-5 UTP
  
  
  
  It is assumed a PC has a 9 pin female connector.
  
  For 25 pin PCs, "alternative" cables or "normal" cables with 25M/9F pin converters can be used.
  
  1A
  PC to Relay # (alternative)
  special
  "Straight"
  
  25pF 25pM
  
  2/25-2/25
  
  3/25-3/25
  
  7/25-7/25
  
  2A
  PC to 7SJ531 (alternative)
  special
  "Swapped"
  
  25pF 9pM
  
  2/25-2/9
  
  3/25-3/9
  
  7/25-5/9
  
  
  
  3A
  PC to PowerTALK (alternative)
  Laplink *
  "Swapped"
  
  9pF 9pF
  
  3/9-2/9
  
  2/9-3/9
  
  5/9-5/9
  
  4/9-6/9
  
  6/9-4/9
  
  7/9-8/9
  
  8/9-7/9
  
  # "Relay" is a Siemens V1, V2 & V3 relay, excluding 7SJ600 and 7SJ531
  
  * A full Laplink cable with handshake signals can provide port power to PowerTALK. A Laplink cable with both 25 and 9 pin plugs on both ends is commercially available in PC shops. The additional 9 pin plug on the PowerTALK side may be removed.