hilscher PKV 50 Series Application guide

Device manual
PKV 50-XXX
Target System for Ethernet-/Fieldbus Applications
Hilscher Gesellschaft für Systemautomation mbH
Rheinstraße 15
D-65795 Hattersheim
Germany
Tel. [phone] - 0
Fax. [phone] - 50
Sales: [phone] - 0
Hotline and Support: [phone] - 99
Sales email: [email protected]
Hotline and Support email: [email protected]
Homepage: http://www.hilscher.com

Index Date Chapter Revision
111.04.02 all created
226.07.02 all revised
Although this appliance has been developed with great care and intensively tested, Hilscher Gesellschaft
für Systemautomation mbH cannot guarantee the suitability of this appliance for any purpose not confir-
med by us in writing.
Guarantee claims shall be limited to the right to require rectification. Liability for any damages which
may have arisen from the use of this appliance or its documentation shall be limited to cases of intent.
We reserve the right to modify our products and their specifications at any time in as far as this contribu-
tes to technical progress. The version of the manual supplied with the appliance applies.
List of revisions 2
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1 Introduction ...................................................................................... 4........
1.1 Scope of Performance ......................................................................... 4........
2 Structure of the Gateway .......................................................................... 5........
3 General Device Description ....................................................................... 6........
3.1 Configuration of the Gateway with the SyCon System Configurator ............................ 7
........
3.1.1 Loading Files into the Gateway .......................................................... 8........
3.1.2 Loading Files on to the Host PC ......................................................... 9........
3.1.3 Deleting Files ........................................................................... 10.......
3.1.4 Setting the IP Address ................................................................... 11.......
3.1.5 Starting Applications .................................................................... 11.......
3.2 Connecting the Supply Voltage (X2) .......................................................... 12
.......
3.3 Interfaces ..................................................................................... 13.......
3.3.1 Ethernet Interface (X4) .................................................................. 13.......
3.3.2 Fieldbus Interface (X6) .................................................................. 14.......
3.3.2.1 PROFIBUS Interface for PKV 50-DPM .......................................... 14.......
3.3.2.2 CAN-Bus Interface for PKV 50-COM, PKV 50-DNM ............................ 14.......
3.3.3 Diagnostic Interface (X3) ............................................................... 15
.......
3.4 Status Displays ............................................................................... 16.......
3.5 Mechanical Dimensions ....................................................................... 17.......
4 Appendix ......................................................................................... 18.......
4.1 Technical Data ............................................................................... 18.......
Table of Contents 3
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1 Introduction
1.1 Scope of Performance
In automation technology it is becoming obvious that Ethernet with the TCP/IP
protocol from the classical conductor field is moving continuously forward into
the fieldbus region. Although attempts are being made to lead Ethernet up to the
individual I/O modules, yet neither all the technical aspects been satisfactorily
solved nor can it be realized with a sufficient effort.
This trend is further strengthened by the requirement for unbroken communicati-
on from the office world up to the individual data point in the industrial installati-
on. Remote maintenance via the Internet is the buzzword now.
This is where our fieldbus Gateway PKV 50 comes into its own. It connects the
Internet-/Ethernet world with the harsh industrial environment of established
fieldbus technology.
It consists of a Master interface connection, which, by means of one of the stan-
dardized fieldbus systems, exchanges data between the connected I/O devices and
the internal process data memory. This data can be accessed for reading and wri-
ting by means of TCP/IP telegrams.
The Microsoft Windows CE operating system is used on the Gateway. Here,
further tasks, such as SoftPLCs, are simply added in order to incorporate extensi-
ons of the functions. The development system is economical to build up and
many engineers are familiar with the development environment. All our inter-
faces are open so that the experienced user can also bring his own applications in-
to use on the Gateway.
A further highlight is the integrated Web-Server. HTML pages can be created on
a corresponding editor and then loaded on to the Gateway. Process data can be
linked via Java Applets. All that is still needed to access the data of the Gateway
via the Internet is a Web Browser such as for example, Microsoft Explorer or
Netscape Navigator.
The configuration of the Gateways is carried out locally with our SyCon System
Configurator via the RS232C serial diagnostic interface or remotely via TCP/IP.
The PKV 50 fieldbus Gateway is now offered for the most important fieldbus
systems.
Customer-specific solutions can be implemented by us or by the customer
himself.
Introduction 4
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2 Structure of the Gateway
Modern communication systems are structured in accordance with the ISO/OSI
reference model (ISO IS 7498). This is based on a 7-layer structure. Here, every
layer makes the services of the next higher layer available but only uses the servi-
ces of the next lower layer itself.
The Gateway fulfills this structure.
The Gateway in the ISO/OSI reference model
Task
IP
Realtime OS
Tasks for Fieldbus
Ethernet
Physical
Fieldbus
TCP
Ethernet
10/100BaseT
Physical
Fieldbus
dependent
Packet
Driver
Windows CE PC
Fieldbus Interface
protocol
Structure of the Gateway 5
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3 General Device Description
The Gateway consists of a basic circuit board with a power supply circuit with
DC/DC transformers in which all the required auxiliary voltages are created. The
fieldbus communication interface is based on the basic circuit board, too.
The Elan SC520 processor board is inserted into the basic circuit board. It con-
tains a built-in timer, interrupt- and DMA-Controller and thus only requires few
external modules. The computing power is adequate for processing even large
quantities of data. Furthermore, the processor ensures efficient software develop-
ment in a high level language. The firmware and the configuration data are stored
in a FLASH-EPROM. This can be programmed within the switching and retains
its data even when the operating voltage is switched off.
The proper function of the Gateway and its internal operating voltage is monito-
red by a Watchdog circuit. In the case of error it triggers a Reset at the processor.
The internal supply voltage is generated by means of a switched mode regulator.
Its input voltage is filtered via a current-transformed toroidal choke and filter ca-
pacitors. A transient diode is available as spike and polarity reversal protection.
In the case of malfunction, a semiconductor fuse switches the device down to a
low residual current until the malfunction is cleared. This means that the chan-
ging of an internal sensitive fuse is dispensed with. Besides this, a charging ca-
pacitor is available that blocks the voltage dips that occur in the switching of
fuses.
The operational readiness and an error in the communication interface are dis-
played by LEDs.
General Device Description 6
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3.1 Configuration of the Gateway with the SyCon System Configurator
The loading of new files on to the Gateway or the setting of the IP address of the
Gateway is carried out by means of the tools contained in SyCon.
In order to be able to use the configuration tools in SyCon, it is necessary to lay
down a configuration with a PKV 50 Gateway in SyCon. Now the menu entry
PKV50-XXX (XXX here stands for the selected fieldbus system) appears in the
Tools menu point. This makes it possible to choose between a serial RS232 con-
nection and a TCP/IP connection.
A crossed RS232 cable is necessary for operation at the serial interface and this
can be obtained from the Company Hilscher (CAB-SRV).
The configuration via TCP/IP can also be carried out via a point to point con-
nection with a crossed cable or, for example, via a Hub with commercial Ethernet
cables.
The Gateway is supplied with a default IP address (see information sheet).
Configuration dialog for the PKV 50-XXX Gateway via TCP/IP
The procedure for the serial configuration or the TCP/IP configuration is basical-
ly the same. First an IP address must be entered into the field provided for it or
the serial interface with which the Gateway is connected must be selected. Then
the Connect switch must be activated. If a valid connection to the Gateway has
been established, then the menu entries and the switches for configuration of the
Gateway are released.
In order to ensure communication via TCP/IP, the TCP/IP protocol on the PC
must be configured in such a way that a connection with the default IP address is
possible (see user manual for Windows NT).
General Device Description 7
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3.1.1 Loading Files into the Gateway
This function enables to load files into the User FLASH of the Gateway and to
carry out applications after downloading or after the start of the operating system.
Before a new application or a new and already available DLL can be downloa-
ded, any running older versions of the application or programs that use DLLs
must be ended. For this purpose, the corresponding running processes can be dis-
played under the Configuration > View Running Tasks menu. If an entry has
been selected, then the Stop Process button can be activated and the selected
process is stopped.
In order to transfer a new file, select the File > Copy to PKV menu or activate
the Copy to PKV button. Select the file to be loaded in the dialog that appears
now.
Dialog for loading files on to the PKV 50 Gateway
The path and name can be entered directly into the Source (PC) text field or se-
lect the path and file via the ... button. The Destination (PKV) field cannot be
edited at present. All the files to be copied are read into the Windows directory of
the Gateway. According to requirements, now mark the buttons Save persistent,
Execute after download and Execute after PKV boot. Now activate the Down-
load button and the software is transferred to the Gateway.
General Device Description 8
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3.1.2 Loading Files on to the Host PC
It is also possible to load files from the Gateway on to the Host-PC. For this pur-
pose select the Copy to PC entry in the File menu.
Dialog for loading files from the PKV 50 Gateway to the Host PC
Now the path of the file that is to be loaded can be entered directly into the Sour-
ce (PKV) field or the contents of the FLASH can be viewed via the ... button and
a file can be selected.
The target place and target name can be entered now in the Destination (PC)
field or selected via the ... button.
After activating the Upload button, the file is loaded onto the Host PC.
General Device Description 9
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3.1.3 Deleting Files
In order to delete files, the menu point File > View Flash Dir can be selected af-
ter building up the connection successfully. A list of files that are permanently
stored in the User FLASH memory is displayed now. Now previously selected
files can be deleted with the Delete button.
General Device Description 10
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3.1.4 Setting the IP Address
Dialog for setting the IP Address
It is possible to allocate a new IP address to the Gateway with the Configuration
> Setting IP address menu. For this purpose, a connection with the Gateway is
necessary as already mentioned.
Now enter the desired valid IP address into the corresponding field. Press the Set
button and the new address is allocated to the Gateway.
If the alteration of the IP was successful, it will be displayed. A request for restar-
ting the Gateway will appear.
Please note that the newly allocated IP address is only valid after a restart of the
Gateway.
3.1.5 Starting Applications
Applications that have already been entered on to the Gateway can also be started
manually. For this purpose the Configuration > Start Application menu has to
be selected. Now enter the name of the application into the field provided for this
purpose and press the OK button.
General Device Description 11
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Note: The Gateway must be
restarted to accept the ad-
dress!

3.2 Connecting the Supply Voltage (X2)
The Gateway requires a supply voltage of 24 Volt. The maximum power con-
sumption is given in section Technical Data. A three-phase rectified supply or a
simple rectified switching with charge capacitor is sufficient. The supply voltage
must be led to ground. It is connected by means of a plug-in screwed clamp. Use
is made of a 3-pin COMBICON plug from the PHOENIX company (MSTB
2,5/3-ST-5,08).
Connection Symbol Signal
1+24V +24V supply voltage
20V Reference potential
3PE Equipment grounding conductor
Connector pin assignment of the operating voltage connection X2
General Device Description 12
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3.3 Interfaces
The PKV 50 Gateway possesses three independent interfaces.
First interface (X3). The first interface can be operated as a diagnosis / configu-
ration interface.
Second interface (X6). The second interface is designed for operation at the
fieldbus.
Third interface (X4). The third interface is used for connection to a
10/100BaseT network.
3.3.1 Ethernet Interface (X4)
Connection Input/
Output Signal - designation
1Output TXDE+
2Output TXDE-
3Input RXDE+
6Input RXDE-
Pin assignment of the Ethernet interface
The Ethernet interface is carried out by means of an 8 pin RJ45 socket for a
10/100BaseT connection.
General Device Description 13
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3.3.2 Fieldbus Interface (X6)
The following tables describe the pin assignment for the individual fieldbus sy-
stems available on the PKV 50 Gateway.
3.3.2.1 PROFIBUS Interface for PKV 50-DPM
Connnection
9 pin D-SUB
socket
Input/
Output Signal designation Signal
- - PE Earth ground
1-PE PNO recommend not to use this
signal
6-VP Power supply
3Input/
Output RXD/TXD-A Data line
8Input/
Output RXD/TXD-B Data line inverse
4Output CNTR-A Repeater control signal
5-DGND Data reference potential
Pin assignment of the PKV50-DPM at the plug X6
3.3.2.2 CAN-Bus Interface for PKV 50-COM, PKV 50-DNM
Connector Input/
Output Signal designation Signal
Connection 9
pin D-SUB plug Connection 5 pin COMBICON
for DeviceNet
- - - PE Earth ground
9 5 -+V 24V external power1
3- - DGND Data reference potential
7 4 Input/
Output CANH Data line high
2 2 Input/
Output CANL Data line low
6 1 -DGND Data reference potential
-3-shield shield of bus cable
Pin assignment of the PKV 50-COM and PKV 50-DNM at the plug X6
General Device Description 14
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3.3.3 Diagnostic Interface (X3)
The connection of a (Host) PC to the Gateway is also possible via the first serial
interface (X3). It corresponds to the RS232C standard according to CCITT or
DIN. However, only the required signals are available.
The control signals are served or evaluated as follows:
RTS is switched to high after the function readiness and not altered again.
CTS must be connected by means of a wire bridge with Pins 4 and 8 of the D-Sub
plug.
The transfer between Host PC and Gateway is at 9.600 Baud and the following
data format: 8 Data bits, 1 Stop bit and even parity. The 3964R procedure is utili-
zed as transfer protocol.
The connection of the PC is carried out with a three-wire cable which must not be
longer than 15 meters. The wiring of the cable is given below. For better interfe-
rence suppression, the cable shielding also on the side of the Host PC should be
grounded over the plug housing.
Connecting cable between Gateway and Host PC
General Device Description 15
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3.4 Status Displays
There are eight LEDs are the PKV 50 Gateway acting as status displays:
Display Color Condition Meaning
SYS, CON, ST1,
ST2 The condition of these LEDs are application-dependent and are described in the corresponding manuals
With a device defect, a cycli-
cal flashing of the RDY-LED
can also be caused by the
continuous accessing of the
Watchdog monitoring.
RDY Yellow On
Flashs cyclically
Flashs irregularly
Off
Gateway ready
Bootstrap loader active
Hardware or system error
Hardware defect
RUN Green On
Flashs irregularly (see
below).
Off
Fieldbus communication running
Parametrizing error (field bus)
No fieldbus communication
ERR / NET / CH_A Fieldbus dependent
STA / MOD / CH_B Fieldbus dependent
After switching on, the Gateway carries out a self-test. If this has been run
through successfully, then the yellow LED RDY is switched on. Otherwise the
LED begins to flash irregularly and the further processing of the program is abor-
ted.
If no fieldbus Firmware is loaded on the Gateway, then the Bootstraploader
shows this by a cyclical flashing of the RDY-LED in a 1-second rhythm. During
the loading of the Firmware the blink rhythm increases to approximately 5 Hz.
If the LED remains off, then there is a defect of the Gateway.
If a fieldbus Protocol Task recognizes a parametrizing error, the Task is displayed
by the RUN-LED in accordance with the following figure.
If there is no error and communication could be started, then the RUN-LED is
switched on.
If the communication operation is blocked, the the RUN-LED remains off.
start-
sign databits with separation-sign -> 1 sec. <- start- sign
The display on the LED is carried
out from left to right
RCS
with
DBM-
Error
Task 1
without
Error
Task 2
without
Error
Task 3
with
Error
Task 4
without
Error
Task 5
with
Error
Task 6
with
Error
Task 7
not
con-
figured
Display of the tasks that have indicated a parametrizing error
General Device Description 16
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3.5 Mechanical Dimensions
The Gateway is built into an aluminum profile housing. This permits direct instal-
lation into the switching cupboard on a carrier rail (TS35 according to DIN EN
50022). The mechanical dimensions and the allocation of the pins are shown in
the following figures.
Front view with pin arrangement on the Gateway
Side view of the Gateway for clipping on to a carrier rail
105
105
General Device Description 17
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4 Appendix
4.1 Technical Data
Processor 586/133 MHz
Memory structure 16 MByte DRAM, 16 MByte FLASH
Ethernet interface potential-free, 10 /100MBaud, 10/100BaseT / RJ-45
Fieldbus interface potential-free
RS485 / 12 MBaud PKV 50-DPM
ISO11898 / 1 MBaud PKV 50-COM
ISO11898 / 500 kBaud PKV 50-DNM
Serial interface non-isolated RS232C
Diagnostic interface
LED displays Operation and communication readiness of the Gate-
way, error on the serial interface or freely programma-
ble by the user.
Operating voltage 18 - 30 V
Power consumption max. 250 mA at 24 V
Operating temperature 0 °C - 50 °C
Protection IP20
Dimensions (L x W x H) 105 x 44 x 105 mm
Installation DIN rail EN 50022
Appendix 18
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