Cocoon PowerTALK 101 User manual

User’s Manual
PowerTALK 101 - Ethernet to Serial converter

PowerTALK 101
2
PowerTALK 101
Configuration, usage and testing guide for PowerTALK 101 communications equipment.
Manual release date: 20 October 1998
Manual Release 2
Supersedes manual, release 1, 15 Oct 98
Supersedes preliminary manual, rev 0.3
Supersedes preliminary manual, rev 0.2
Supersedes preliminary manual, rev 0.1
PowerTALK 101 Firmware release 1.00
PT.EXE Configuration software, release 1.01
Contact address:
Cocoon Creations cc
PO Box 380
Groenkloof
0027
South Africa
Internet: www.cocoon-creations.com
Support: [e-mail]

PowerTALK 101
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Table of Contents
TABLE OF CONTENTS ............................................................................................................................. 3
FOREWORD................................................................................................................................................ 5
INTRODUCTION........................................................................................................................................ 7
BRIEF DESCRIPTION..................................................................................................................................... 7
PC CONFIGURATION TOOL PT.EXE & PT98.EXE ...................................................................................... 7
YEAR 2000.................................................................................................................................................. 7
ORDERING OPTIONS..................................................................................................................................... 8
Default specifications for PowerTALK 101:...........................................................................................8
Custom specifications for PowerTALK 101: .......................................................................................... 8
AVAILABLE POWERTALK 101 MODELS ..................................................................................................... 8
DISCLAIMER ................................................................................................................................................ 8
POWERTALK 101 OVERVIEW ............................................................................................................... 9
FEATURE OVERVIEW.................................................................................................................................... 9
FUNCTIONAL OVERVIEW OF POWERTALK 101......................................................................................... 10
SCHEMATIC OVERVIEW OF POWERTALK 101........................................................................................... 11
NETWORK TOPOLOGY OVERVIEW OF POWERTALK 101 ........................................................................... 12
PHYSICAL PROPERTIES....................................................................................................................... 13
POWERTALK 101 PICTURE....................................................................................................................... 13
LED, PLUG AND SWITCH LAYOUT.............................................................................................................. 13
DEVICE AND TERMINAL IDENTIFICATION................................................................................................... 14
DIMENSIONS.............................................................................................................................................. 14
REAR DIN RAIL......................................................................................................................................... 14
ADDITIONAL POWER SUPPLY OUTPUTS ...................................................................................................... 14
FACE PLATE CARE &MAINTENANCE ......................................................................................................... 14
INTERNAL CONNECTIONS AND LAYOUT ..................................................................................................... 15
FUSES &LINKS.......................................................................................................................................... 16
BATTERY REPLACEMENT........................................................................................................................... 16
JUMPER SETTINGS...................................................................................................................................... 17
Power supply board.............................................................................................................................. 17
Communications processor board........................................................................................................ 18
ELECTRICAL CONNECTION TO POWERTALK ............................................................................. 19
EXTERNAL WIRING ................................................................................................................................... 19
EARTH WIRING.......................................................................................................................................... 19
ISOLATION IN THE POWERTALK 101 BOX................................................................................................ 20
POWERTALK 101 SPECIFICATIONS.................................................................................................. 21
MAIN PROCESSOR COMPONENT ................................................................................................................. 21
MAIN POWER SUPPLY ................................................................................................................................21
POWERTALK 101 SPECIFICATIONS........................................................................................................... 22
POWERTALK 101..................................................................................................................................... 22
CONNECTING POWERTALK 101 TO A NETWORK........................................................................ 25
QUICK START GUIDE.................................................................................................................................. 25

PowerTALK 101
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Power Supply........................................................................................................................................ 25
Networking ........................................................................................................................................... 25
CHANGING MORE ADVANCED PARAMETERS USING PT.EXE...................................................................... 26
PASSWORDS............................................................................................................................................... 27
PT.EXE – POWERTALK COMMAND LINE INTERFACE .............................................................................. 28
PT.EXE EXAMPLES................................................................................................................................... 28
Confirm your PC IP address ................................................................................................................ 28
List all available PowerTALK units...................................................................................................... 29
Set a PowerTALK unit name................................................................................................................. 29
Change some parameters ..................................................................................................................... 29
Change a port/channel allocation ........................................................................................................ 29
Accept all changes................................................................................................................................ 29
POWERTALK98–WINDOWS GUI SOFTWARE......................................................................................... 30
POWERTALK 98 EXAMPLES ..................................................................................................................... 31
NETWORK TOPOLOGY ............................................................................................................................... 32
POWERTALK 101 CONFIGURATION.......................................................................................................... 34
PRE-CONNECT CONFIGURATION................................................................................................................. 34
Serial connection cables....................................................................................................................... 34
Network connection: IP address setting............................................................................................... 35
Other settings on PowerTALK 101....................................................................................................... 36
CONNECTING TO THE PHYSICAL NETWORK................................................................................................ 36
10-BASE-T............................................................................................................................................ 36
COMMISSIONING AIDS......................................................................................................................... 37
LED INDICATIONS..................................................................................................................................... 37
Normal LED indications on face plate:................................................................................................37
Indications on inside of box, only visible when cover is removed:....................................................... 37
TESTS ........................................................................................................................................................ 38
Tests using standard networking protocols:......................................................................................... 38
Tests available using PT.EXE............................................................................................................... 38
Tests available using PowerTALK 98 under Windows 95 or NT.......................................................... 38
TESTING PROCEDURE................................................................................................................................. 39
EASY FUNCTIONALITY TEST -LOOPBACK TEST: ........................................................................................ 40
SETTING AND CONFIGURING POWERTALK 101........................................................................................ 42
PRACTICAL CONNECTION EXAMPLE –ADDRESS TYPE SERIAL DEVICES..................................................... 43
PRACTICAL CONNECTION EXAMPLE –NON ADDRESS (OLD)TYPE SERIAL DEVICES ................................... 44
PRACTICAL MULTI NODE EXAMPLE............................................................................................................ 45
TECHNICAL DETAIL.............................................................................................................................. 47
SETTINGS FOR POPULAR SIEMENS &GEMULTILIN EQUIPMENT ............................................................... 47
CHANNELS................................................................................................................................................. 47
POTENTIAL POWERTALK LOCK-UPS ........................................................................................................ 48
Endless loop.......................................................................................................................................... 48
Loss of communication to configure PowerTALK 101......................................................................... 48
TESTING SYSTEM WATCHDOG.................................................................................................................... 49
USING POWERTALK 101 WITH BRIDGES AND ROUTERS ........................................................................... 49
POWERTALK 101 PROTOCOL ................................................................................................................... 50
OTHER PRODUCTS AVAILABLE IN THE POWERTALK FAMILY............................................. 51
HISTORY OF CHANGES TO THIS MANUAL,FROM RELEASE 1....................................................................... 52
Release 2............................................................................................................................................... 52
NOTES......................................................................................................................................................... 53

PowerTALK 101
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Foreword
The PowerTALK product family, available from www.cocoon-creations.com,is
a
modular set of tools that enable engineers and process controllers to centralise
the monitoring and management of proprietary industrial equipment.
COCOON has recognised that there is legacy equipment in production today that
is robust, reliable and relatively inexpensive, however, such equipment often
comes with limited ability on-board for centralised monitoring and management.
The PowerTALK tool set provides the intelligence needed to connect such
equipment with modern IT networks enabling central control and management of
the device.
PowerTALK conforms to industry standards, for example:
ÿIndustry standard, routable, communication protocol: TCP/IP (The
international standard)
ÿIndustry standard connectivity: 10BASET Ethernet as default (others available)
ÿIndustry standard lower level protocols: RS-232, RS-485
ÿNo restriction to higher level protocols passed through

PowerTALK 101
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PowerTALK 101
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Introduction
Brief description
PowerTALK 101 is an Ethernet-to-Serial Converter that packages serial data into TCP/IP packets
that are transmitted through a standard Ethernet port and onto the corporate or industrial network
/Intranet/Internet.
It simultaneously also does the inverse: TCP/IP packets that are addressed to PowerTALK 101’s
IP Address (user definable) is accepted by the device and repackaged into the original stream of
serial data and is sent to the appropriate serial port.
The distance between any two PowerTALK 101 devices is irrelevant, as long as the TCP/IP
packets do not time out in transit, and the user application can accept such delays introduced by
the carrier network route. Given effective communication links, one PowerTALK 101 may,
hypothetically, be on one side of the globe, while the other may be in the same office block.
Each PowerTALK 101 device has 2 serial ports that may both be connected to conventional serial
links / separate serial communication networks on site. In combination with other equipment
such as the PowerTALK 103 RS-485 converter, each serial port may further be expanded to
more serial devices.
PC configuration tool PT.EXE & PT98.EXE
PowerTALK/DOS and PowerTALK 98 are supplied free of charge. This software is used to track
PowerTALK 101 connections, to functionally test the system, to configure Ethernet type
information, to configure serial ports and set up Ethernet connections remotely.
PowerTALK 98 and PowerTALK/DOS (PT.EXE) have the same configuration abilities, but
PowerTALK 98 has easier testing features. PowerTALK 98 makes use of the advantage of the
GUI interface of Windows while PowerTALK/DOS makes use of a command line interface.
PowerTALK 98 connects via the PC serial port, PT.EXE via the PC Ethernet port.
Information on this software can be found in the on-line help in both PowerTALK 98, and PT.EXE
v1.01 on the distribution disk. (Run PT.EXE –h). Also see complete options and examples on
page 28.
Year 2000
The PowerTALK tool set is Y2K compliant – third party software used to control devices may not
be and therefore it is recommended that tests are conducted by clients to ensure interoperability
on critical Y2K or subsequent dates.

PowerTALK 101
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Ordering options
Default specifications for PowerTALK 101:
Power Supply: 230VAC
Network Connection: 10-BASE-T Ethernet
Serial Connectors: 2 off 9-pin D-type serial connectors,
Broadcast mode: UDP
The PowerTALK unit is marked at the back with the relevant information, including the standard
fixed IP address. See page 14 for Device and terminal identification.
Custom specifications for PowerTALK 101:
The following options may be specified for PowerTALK 101 at time of order: At our discretion,
larger orders may justify more options than those stated below.
PT101-230A-- 230 VAC isolated power supply
PT101-230B-- Additional 10VDC output, ext. use
PT101-220D-- 220 VDC isolated power supply
PT101-110D-- 110 VDC isolated power supply
PT101-E-- Additional 10VDC output, ext. use
PT101--100- Firmware version, eg. 1.00
PT101---N No internal GPS clock
PT101---A DB9, DB9 serial connections
PT101---B DB-25, DB-25 serial connections
PT101---0No on-board printer
PT101---A RJ-45 10-Base-T
PT101---B BNC 10-Base-2
PT101Model number A,B, …
Available PowerTALK 101 models
101 UDP type IP protocols, broadcast mode
101B UDP type IP protocols, broadcast mode, peer to peer
101C TCP/IP type protocols, broadcast mode, peer to peer, packet numbering, error detection
Disclaimer
COCOON Creations cc cannot be held responsible for the ability or inability of operators and / or
software tools to manage specific devices properly. Neither can COCOON Creations cc be held
responsible for any network, carrier or equipment not performing as anticipated. COCOON
Creations cc can not be held responsible for any direct, indirect or subsequent damages or losses
due to the operation or lack there-of, of any device or software obtained from us.

PowerTALK 101
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PowerTALK 101 overview
Feature overview
•PowerTALK 101 can transport any serial protocol over standard Ethernet networks using
standardised transmission methods
•PowerTALK 101 can be Installed at any point on an Ethernet network
•Communication parameters can be changed from any port: local, remote or networked
•PowerTALK 101 is delivered with a standard IP to which it always respond.
•PowerTALK 101 can be configured with a second IP to fit into your network scheme.
•Configuration parameters such as IP and baud rate are stored in non-volatile memory
•Any port can be moved, replaced or upgraded without disruption to the network
•Data is available anywhere on the network - across campus or across countries
•Supports full or half duplex connections
•Data can be addressed to one port or to all ports simultaneously, depending on the
configuration
•Individually configurable PowerTALK device passwords are implemented for network
access control
•Individual local serial port passwords fixed for local access
PowerTALK 101 re-establishes each logical connection upon restart after a network or power
failure. PowerTALK 101 controls remote equipment. PowerTALK 101 gives Ethernet sites total
system uniformity. Now you can manage connections between non-Ethernet equipment with the
ease of Ethernet.

PowerTALK 101
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Functional overview of PowerTALK 101
PowerTALK 101 is a network protocol converter, one unit having at least a serial port and an
Ethernet port. All PowerTALK 101 models utilise the TCP/IP protocol suite for communication and
configuration.
PowerTALK 101 uses UDP broadcast packets to effectively combine a campus wide Ethernet
network into one virtual RS-232 multi-drop network. Each port on each PowerTALK 101 device is
assigned to a virtual
channel , and all data received on this port will be transmitted into this
channel, and all other ports connected to this
channel , will receive all data traffic. UDP broadcast
packets will normally not be carried by routers and bridges, and can only be used on a single or
virtual segment.
PowerTALK 101B additionally has UDP peer to peer routed packets for one-to-one
communication. PowerTALK 101C also adds TCP peer to peer connections, for one-to-one
communication over unreliable and changing links.
PowerTALK 101 / 101B / 101C Data UDP broadcast single virtual segment
PowerTALK 101 / 101B / 101C Configuration UDP peer to peer across router
PowerTALK 101B / 101C Data UDP peer to peer across router
PowerTALK 101C Data TCP peer to peer across router, advanced

PowerTALK 101
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Schematic overview of PowerTALK 101
Ethernet LAN segment, TCP/IP, UDP, etc.
TCP/IP Ethernet port - to communications master
AC Power
Isolated PSU Communications
Processor
Non isolated RS-232 ports for connection to
communication equipment in the field
Serial ports: Serial 1 Serial 2
Encapsulated
Data, see p50
Raw serial Data
PT 101
Encapsulated
Data, see p50
Raw serial Data
PT 101

PowerTALK 101
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Network topology overview of PowerTALK 101
PC Hub (UTP/ Thinnet)
Configuration PC
On Ethernet
Ethernet
PowerTALK 101
RS-232 Serial devices
RS-232
Master PC
On COM port

PowerTALK 101
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Physical properties
PowerTALK 101 picture
Front view Rear view
LED, plug and switch layout
Reset
Green:ON Red: PowerTALK Failed
Serial 1
Green: Transmit Red:Receive
Serial 2
Green: Transmit Red:Receive
Ethernet
Green: Transmit Red:Receive
Reset Press to restart all on-board processors in case of suspected system
malfunction, or LED test
Serial 1 Serial Port 1: 1200 – 19200 bps, 5,6,7,8 bits, NOE parity, 1,2 stop bits DB-9
Serial 2 Serial Port 2: 1200 – 19200 bps, 5,6,7,8 bits, NOE parity, 1,2 stop bits DB-9
Ethernet Ethernet medium – 10 Mbps 10-BASE-T RJ-45

PowerTALK 101
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Device and terminal identification
Typical label for the 230VAC model, mounted on rear of PowerTALK 101:
Dimensions
PowerTALK 101 maximum dimensions.
Above dimensions exclude the terminal rail at the back of the PowerTALK 101 box.
Rear DIN rail
The 35mm DIN rail is provided for convenience, to mount up to two PowerTALK 103 RS-485
converters or other third party rail mount equipment such as power supplies, etc.
Additional power supply outputs
An additional power supply unit for external equipment with mounting holes 90mm x 90mm may
be mounted inside or outside the box, using the 4mm diameter holes provided. Such power
supply may be obtained from third parties, or from COCOON. See pages 8, 17 and 21.
Face plate care & maintenance

PowerTALK 101
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The front surface is of brushed stainless steel, and shows fingerprints easily on the textured
finish. To remove, use a cloth with alcohol or spirits. Take care not to allow the volatile fluid to
come into contact with the vinyl stickers on the surface of the front plate.
When wiping the front panel surface, wipe horizontally; in the same direction as the brush finish
texture for the best results.
Internal connections and layout
PowerTALK 101 seen from the front, with its faceplate removed
The main elements of PowerTALK 101 can be seen as follows:
A Communications processor 80486
B Power Supply 5V 4A isolated
CLEDplug DB-25
D Spare power supply mounting holes 90 x 90 mm
H Reset button Reset
I Spare communications processor card slot
for future expansion 80486 or Pentium

PowerTALK 101
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Fuses & links
•One PC board mounted 5mmx20mm fuse, 1A rating, fast blow
This fuse is for PSU overload protection
•Between terminals X1:2 and X1:6, a fuse with 3A rating, slow blow
This fuse is for short circuit protection against possible short circuit inside the box
•Between terminals X1:1 and X1:5, a link terminal
A link is used to isolate the Neutral or Negative power supply if needed.
•Between terminals X1:3 and X1:7, a link terminal
A link is used to connect the signal ground to the chassis ground.
Battery replacement
The PowerTALK 101 unit has a built in battery for the purpose of keeping time when the power
supply is removed. The lithium battery is expected to last for at least 10 years.
It is easily replaced by opening the front cover. The battery location is shown on page 17,
indicated as “BAT”.

PowerTALK 101
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Jumper settings
PowerTALK 101 contains two printed circuit boards:
Power supply board
No jumpers or options on board
A. One 2-pin, 0.3” spaced connector connected to power input
This connection is connected to terminals X1:1,5 and X1:2,6.
B. One 2-pin, 0.1” spaced connector with output 12VDC, 50mA
This supply is not needed by PowerTALK 101, but can be used by the user’s
equipment
C. One set of screw terminals for output 5VDC, 4A. N.B. Observe polarity:
The RED bootlace lug is +5V, whilst the BLUE bootlace terminal is 0V.
The communications common signal, 0V, can be switched to earth by
the disconnect terminal between X1:3 and X1:7
CB A
PowerTALK 101 230VAC power supply

PowerTALK 101
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Communications processor board
Jumper settings are not user configurable, and are to be as per diagram below:
Connections
A. Port 1 to SERIAL 1 (green CAT-5 UTP cable) to front plate connector
B. Port 2 to SERIAL 2 (blue CAT-5 UTP cable) to front plate connector
C. RJ-45 to ETHERNET (yellow CAT-5 UTP cable) on front plate
D. 2-pin J3 to reset button on front plate
E. LED lead connector inside box
F. 4-pin 5VDC input power connector
Observe polarity according to board markings “+5V 0V”.
G. Lithium battery
Jumpers on Communications Processor
A
B
D
E
F
G

PowerTALK 101
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Electrical connection to PowerTALK
External Wiring
PowerTALK 101 only needs three power connections, i.e. earth, L and N. In the case of the DC
powered model, it is earth, V+ and V-.
NLEarth
230VAC Power Input
Earth Wiring
All metal panels in the PowerTALK 101 box are earthed to the star point at the back of the box.
The logical earth (low noise earth point) used by the internal PowerTALK 101 electronic cards,
can optionally be connected to the system earth. The blade disconnect terminal switch between
terminals X1:3 and X1:7 performs this function.