HW Group I/O Controller 2 User manual

I/O Controller 2 Manual
HW group
www.HW-group.com
1/ 42
I/O Controller 2
MANUAL

I/O Controller 2 Manual
HW group
www.HW-group.com
2/ 42
Safety information
The device complies with regulations and industrial standards in force in the Czech Republic and the
European Union. The device has been tested and is supplied in working order. To keep the device in
this condition, it is necessary to adhere to the following safety and maintenance instructions.
The device must not be used in particular under any of the following conditions:
•The device is noticeably damaged
•The device does not function properly
•Unfastened parts can move inside the device
•The device has been exposed to moisture or rain
•The device has been serviced by unauthorized personnel
•The power adapter or power supply cable are noticeably damaged
The manufacturer warrants the device only if it is powered by the supplied power adapter or an
approved power supply.

I/O Controller 2 Manual
HW group
www.HW-group.com
3/ 42
I/O Controller 2
Ethernet –RS-232/485 + inputs and outputs
I/O Controller 2 is an Ethernet-enabled device with 8 digital inputs,
8 digital outputs and a RS-232/485 serial interface.
All interfaces are accessible over TCP/IP using a M2M
protocol.
Two devices can be connected against each other
(Box-2-Box mode) in order to extend the digital and
RS232 signals over the computer network.
Basic features
•1x full RS-232 or RS-485 serial port accessible over the Ethernet.
•The remote port can be controlled with a virtual driver for Windows just like, for example,
COM 5 (a Windows XP / Vista / Windows 7 / Server 2003 / Server 2008 / x64 driver is
available free of charge). Compatible with RFC2217.
•100 Mbps Ethernet interface –100BASE-Tx, RJ 45
•Support for TCP/IP terminal, TELNET –NVT type (Network Virtual Terminal)
•Two devices can „tunnel“ the serial port, 8 inputs and 8 outputs over the Ethernet
•Web-based interface for configuration
•Wide range of supported serial interface parameters:
•Communication speed configurable from 300...115200 Bd
•Handshake (CTS/RTS, Xon/Xoff, none)
•Full serial port (Cannon DB9M - RxD, TxD, CTS, RTS, DSR, DTR, RI, CD, GND)
•Support for 7th to 9th parity bit (9th parity bit transferred over the Ethernet)
•SDK (Software Development Kit) is available for the device with examples for MS Visual
Basic, Delphi, Borland C++, JAVA, PHP and more

I/O Controller 2 Manual
HW group
www.HW-group.com
4/ 42
Technical specifications
RS-232 serial port
+ Data bits
7 or 8 or 9
+ Stop bits, parity
1 or 2, None / Odd / Even / Mark / Space parity
+ Baudrates
50..115.2 kBd –entire range
+ Data flow control
XON/XOFF, CTS/RTS, None
+ Interface
1x DB9M (RxD, TxD, CTS, RTS, DSR, DTR, RI, CD, GND)
+ Implemented RS-232 signals
RxD, TxD, CTS, RTS, DSR, DTR, RI, CD
RS-485 serial port
+ Termination
None (We recommend external termination 120-470Ω)
+ Isolation
RS-485 line not optocoupled to the device’s power supply
- electrically isolated RS-232/485 to Ethernet (1000 V)
Digital inputs & outputs
+ Input type
Dry contact input
+ Logic LOW voltage
0 .. 3V
+ Log. HIGH voltage threshold / “on” current
from 5V / 5mA to 20V / 25mA
+ Max. input voltage and current
up to 40V / 50mA / 1 second
+ Isolation Voltage
max. 50V to power supply
+ Sampling period
10 ms
+ SW control of inputs and outputs
Inputs and Outputs controlled over a NVT-based M2M protocol
(extended RFC2217) –short 7-byte binary commands over TCP/IP
+ Output type
Darlington transistors with common emitter, suppression diodes
max. 50V, max. 500mA / 1 output and max. 1500mA / all 8 outputs
Ethernet port
+ Interface
RJ45 100BASE-T / 100 Mbit/s
+ Compatibility
Ethernet: Version 2.0/IEEE 802.3
+ Supported protocols
IP: ARP, TCP + NVT (Network Virtual Terminal)
+ TCP connection closing
Data –5s timeout (with NVT –ACK/NOP support)
Physical parameters & Environment
+ Temperature & humidity
Operating: 0 –65 °C (32 – 149 °F)
Storage: -10 to 85°C (14 to 185°F), humidity 5 to 95 %
+ Power supply requirements
8-30V / Max. device current consumption 200 mA DC
- barrel (coaxial) power connector, GND on the shield
+ Dimensions / Weight
120 x 94 x 25 [mm] (H x W x D) / 260 g
Note: This parameter table is only indicative.
For a valid table, see the specifications for the particular device model.

I/O Controller 2 Manual
HW group
www.HW-group.com
5/ 42

I/O Controller 2 Manual
HW group
www.HW-group.com
6/ 42
Connectors
Connector pinout
RS-485 Port
Pin
Signal
A
+ (A>B)
B
-
RS-232 Port
Pin
Signal
1 <-
CD
2 <-
RxD
3 ->
TxD
4 ->
DTR
5 --
GND
6 <-
DSR
7 ->
RTS
8 <-
CTS
9 <-
RI
Cannon 9 - Male
t
h
e
r
n
e
t
:
P
o
w
Power LINK

I/O Controller 2 Manual
HW group
www.HW-group.com
7/ 42
DIP 1
DIP 2
Function
ON
OFF
RS-232 Setup mode (9600 8N1) Ethernet is disabled
OFF
OFF
Serial port in the RS-232 mode
OFF
ON
Serial port in the RS-485 mode
check the &R and &H parameters (recommended: &R3 &H1)
LEDs:
Power –green..................................... External power connected
LINK –amber.................................... Ethernet interface activity
Status –green..................................... Device starting up, firmware upgrade
Setup –red......................................... Device in serial Setup mode
INx –green ......................................... Input x is closed
OUTx –red......................................... Output x is closed

I/O Controller 2 Manual
HW group
www.HW-group.com
8/ 42
Digital Inputs & Outputs wiring
•GND –device ground.
•PWR –device power (max. 200 mA).
The device can be powered from barrel power connector (front panel) or from the I/O
connector PWR + GND pins (200 mA internal fuse = suitable only for testing purposes).
•I.GND –common ground for optocouplers.
•I.0 to I.7 - 8 optocoupled inputs 5-20V
All 8 inputs are realized using common ground optocouplers (I.GND pin). The pins can then
be controlled using the contacts together with the POWER pin, which has the power adaptor
voltage (connect I.GND with GND).
Warning: The digital input voltage range is 5 -20V, but be careful for max total current thought
I.GND pin which is 200mA for all digital inputs (cca 25 mA per singe Digital Input).
•O.COM (Common) –Overvoltage output connected to the plus pole of the power source. This
can be useful when you want to control a relay from this output.
•O.0 to O.7 - 8 open collector outputs, with common diode overvoltage protection.
The outputs a realized using 8 open collector transistors. Two outputs are internally connected
to a relay, which contacts are also led out to the device’s connector. The protecting diodes are
connected to the “common” pin, which should be connected to the plus pole of the next device
(for example a relay). This way the pins can be protected against load peaks.
PIN
Description
8x INPUTS
GND
Ground
1
OUT0
Output transistor 0
2
OUT1
Output transistor 1
3
OUT2
Output transistor 2
4
OUT3
Output transistor 3
5
OUT4
Output transistor 4
6
OUT5
Output transistor 5
7
OUT6
Output transistor 6
8
OUT7
Output transistor 7
9
O.COM
Common wheeling diodes
10
8x OUTPUTS
IN0
Input 0 (5-15V)
11
IN1
Input 1 (5-15V)
12
IN2
Input 2 (5-15V)
13
IN3
Input 3 (5-15V)
14
IN4
Input 4 (5-15V)
15
IN5
Input 5 (5-15V)
16
IN6
Input 6 (5-15V)
17
IN7
Input 7 (5-15V)
18
I.GND
Opto-couplers ground
19
PWR
Ext. power supply
20
1
20

I/O Controller 2 Manual
HW group
www.HW-group.com
9/ 42
Quick SETUP
Connecting the cables
•Connect the supplied power
adapter to an electrical outlet.
•Set DIP1 and DIP2 to OFF.
•Connect the device to the
Ethernet.
•Connect the power adapter to
the power connector at the
device.
•If the power is OK, the green
Power LED lights up.
•If the Ethernet connection works
properly, the LINK LED lights
up, and then flashes whenever
data transfer takes place
(activity indication).
Configuring the IP address
•Start the “HerculesSetup.exe” utility. It is available on the DVD (included in the “set” package)
or for free download at www.HW-group.com.
•In the “UDP Setup” tab, click “Find modules”. The MAC address of the device appears in the
left column. Click the MAC address and set the required parameters (at least the IP address,
mask and gateway).
•Make sure that “Enable TCP Setup” is checked. Click “Set module” to save the parameters to
the device.
•You have now configured the IP address and other networking parameters and you can work
with the device.
MAC address not visible in the list?
LINK LED did not light up or the device does not respond? Please double check the following.
- Does your Ethernet network support 10 Mbps devices?
- Are you using a correct TP cable (straight-wired TP Patch when connecting to an Ethernet
switch, crossover cable when connecting to a PC)?
- Check the DIP switch settings (all should be OFF).
- Check your power adapter, make sure the Power LED is on.
- Check the firewall settings at your PC.

I/O Controller 2 Manual
HW group
www.HW-group.com
10/ 42
Configuring the device over WWW
In the UDP Setup tab, click the correct MAC address and press Open in the WEB browser.
You need to log in to access the configuration.
The default password is “admin”+ “1234”
Default login:
▪admin
▪1234

I/O Controller 2 Manual
HW group
www.HW-group.com
11/ 42
Setting up the device using TCP Setup
•Change to the “TCP Client” tab and enter the configured IP address. Set the TCP Port to 99.
•Click “Connect”. The listing on the left displays the “WEB51>” prompt. Click inside this pane
and press ENTER. The window displays the current configuration.
•To set a parameter, enter the
corresponding letter and the desired
value (for example “I192.168.6.8” to
set the device IP address). To show
the help for a command, enter the
command and a question mark, and
press ENTER –for example, “I?
<Enter>“. All the settings are
described in detail later in this
manual.
•After setting the parameters, use R
for Reboot and press “Disconnect”
to disconnect from the device. The
device restarts.
•Note: TCP Setup can be disabled
with the “Enable TCP setup” option.
When unchecked, the device
refuses connections to port 99.
Setting up the device using a RS-232 terminal
If you do not have Windows or our Hercules utility available, you can set up the device over RS-232
using any terminal.
•Set DIP1 = ON, DIP2 = OFF.
•Connect RS-232 (port 1) to a PC using the
supplied LapLink cable.
•Open your favorite terminal program (e.g.
Hyperterminal), choose the correct serial
port and configure it to 9600 8N1.
•Connect the power adapter to the
electrical outlet and to the device.
•If the power is OK, the green Power LED
lights up.
•If the serial cable and terminal program
are working, the text menu for configuring
the device appears.
Continue by following the steps as in the previous
case.

I/O Controller 2 Manual
HW group
www.HW-group.com
12/ 42
Quick control of inputs and outputs
This chapter shows how to read a digital input and set a digital output to a desired value. We assume
that a test board supplied with device samples is used.
The following assumes that you know how to enter the setup mode (RS-232 Setup or TCP Setup at
port 99). The respective steps were described in the previous sections.
•Set DIP1 = OFF, DIP2 = OFF, connect the test board to the connector and turn on the
device.
•Change to the “UDP Setup” tab, find the devices, and make sure that the “Enable TCP setup”
and “Enable NVT” options in the lower left-hand portion next to the MAC list are checked for
the respective device . If not, check both options and save your settings to the device.
•Double-click the IP address in the “UDP Setup” tab and change to the “Test mode” tab. The
double-click action should transfer the IP address and port to the Test tab. If this does not
happen, enter the values manually.
•Click “Connect”. The listing at the
left-hand side displays Connecting,
followed by one or three NVT
commands in the received data. All
recognized commands are
displayed in blue.
The image shows the listing and the
configuration options of the
Hercules utility. To invoke the
menu, right-click inside the
receiving pane or the transmitting
pane.
•At this point, click “Read” in the
lower right-hand corner to read the
inputs (8 switches at the test
board). Input states are indicated by
the virtual LEDs D0 to D7,
respectively. States can be inverted
with the “LED polarity” option.
•The D0 –D7 checkboxes set the corresponding outputs. The first command sets all outputs to
defined states, subsequent commands set individual bits. Outputs can be again inverted using
the “Inversed” option.
The “Write together” option does not send commands immediately when an output is selected;
instead, outputs are set after clicking “Write”.
•When “Show I/O commands” is enabled, notice the I/O Controller control sequences in the
incoming and outgoing panels. This makes it easy to test the commands.
•Enter “FF F6” to the Send lines at the bottom, check HEX and click the corresponding Send
button to send this command. The receiving pane should show “<WEB51 HW 4.7 SW 2.J SN
00A608 #01>” or something similar. You have just sent your first NVT command requesting
“Are You There” identification, and the I/O Controller replied with its HW and SW version. The
SN number consists of the last three bytes of the MAC address.
•If the TCP connection is closed while working (red message “Connection refused by
remote host”), click “Connect” to reconnect. The module uses a rather short timeout (50 s)
for manual control.

I/O Controller 2 Manual
HW group
www.HW-group.com
13/ 42
Setting up the device –Frequently Asked Questions
•Ethernet no longer works but LINK is lit.
Perhaps the device was left in the “RS-232 Setup” mode that is activated by setting DIP1 = ON? In
this mode, the Ethernet does not respond. Set DIP1 = OFF and restartthe device by disconnecting
the power supply for at least 3 seconds.
•RS-485 communication does not work.
Make sure that termination resistors (120 –470 Ohms) are present at the line or at the
connector.
•When using a RS485 converter, configure &I1 or &I2 and rememberto turn on HALF DUPLEX
using &H1.
•I need to supplypower to a RS-232 application.
If you don’t need to control data flow (HW handshake) but need to power a device connected to the
serial port (max. 5 –10 mA), power your application from the RTS output (pin 7 at the RS-232
connector). The &R0 parameter (&R: RS485/RS422 control) in the setup connects approximately
+8 V to +12 V to this pin.
•Digital inputs and outputs cannot be controlled. RS-232 data work fine.
Most likely, “NVT” is disabled. Check this at the “UDP Setup” tab in the Hercules utility, in the TCP
Setup, or in the RS-232 Setup.
•5-second timeout is too short to work with, is it possible to do something about it?
Yes, enable “Keep connection” in the Setup. I/O Controller then sends a command every 6
seconds that appears as “NVT: NOP”in the receiving pane, and the connection does not timeout.

I/O Controller 2 Manual
HW group
www.HW-group.com
14/ 42
HW VSP –virtual serial port
Virtual serial port driver is a software tool that adds a virtual serial port (e.g. COM5) to the
operating system and redirects data from this port via the Ethernet network to another
hardware interface.
•The driver works in Windows XP, Vista, Windows 7, Windows 2003 Server, Windows 2008
Server, including 64-bit versions.
•If the device supports RFC 2217 (NVT), you can set the remote serial port parameters (speed,
parity, stop bits).
•The communication can be recorded to a LOG file for easier debugging.
•It is possible to create multiple virtual serial ports on a single computer (COM5, COM6,
COM7) by starting VSP.EXE from the command line with appropriate parameters.
Using HW VSP with I/O Controller
•Install HW VSP (“HW_VirtualSerialPort” directory on our CD). When installing, make sure to
check the option to install the second part. After installation, restart your PC.
•Make sure that NVT is enabled at the UDP Setup tab in the Hercules utility. If not, enable
NVT and save the settings.
•Start HW VSP and find the devices at the “UDPsetup” tab. Select the MAC address of the
device and click “Use this IP”. Change to the “Virtual SP” tab. The IP and Port should be
already set. This search via UDP Broadcast works only on a local network.
•Select a serial port to create from the COM1 to COM20 range and click “Create COM”. The
“LAN status” pane shows whether the device has been
found. If so, the virtual serial port is created.
•As soon as you start any application that opens the selected
virtual serial port (COM5 in this example), the HW VSP
driver establishes a connection with the I/O Controller,
configures the remote port (speed, parity, number of bits,
handshake) to match the virtual serial port being opened,
and starts transferring data.
Some applications have problems with serial port numbers
higher than COM4. You can always use Hyperterminal in
Windows, the Serial tab in the Hercules setup utility, or the
“Terminal.exe” utility originating from Slovenia and available
on the CD in the utils directory.
•Select the I/O Controller sub-tab in the “Binary I/O” tab. Here
you can set and read digital inputs and outputs without additional software.

I/O Controller 2 Manual
HW group
www.HW-group.com
15/ 42
HW VSP settings
TEA Key pane
You can use TEA authentication to secure TCP/IP access. The
same TEA key must be set and enabled at both sides of the
communication.
NVT pane
Enables RFC2217 and detection of our remote ports. Remember
to activate NVT support on the remote device as well.
•NVT filter –Filters out NVT control characters from the data flow.
•NVT port setup –Configures the remote port parameters via control
commands to match the VSP in your PC. For example, if your
terminal program (e.g. Hyperterminal) changes the baudrate to 19200
Bd and this box is checked, the VSP driver sends a NVT command
(according to the RFC 2217 standard) to change the baudrate of the
remote TCP/IP serial port.
•Keep Connection –Keeps the TCP/IP connection open even after
50 seconds of inactivity.
Main HW VSP parameters
•Log enabled
The VSP driver logs the virtual serial port activity to “C:\serialport.log”.
•TCP server mode
Activates VSP as a TCP/IP server. The driver then behaves as a TCP Client/Server device –
the first side to receive any data switches to Client mode and establishes the connection.
The incoming TCP server port is configured at the main “Virtual SP” tab. We recommend
using port numbers higher than 1025.
•Create port on start VSP
Automatically creates virtual ports when the driver is started. To create virtual ports at
Windows startup, the “Start VSP on boot” box must be checked, too.
•Hide on startup
Hides VSP to to the system tray. The VSP icon is accessible near the clock.
•Don't create port if ping fail
Before creating the virtual serial port, tests if the device IP address responds.
•Connect to module if port is closed
If the virtual serial port is not in use by any application, checking this box can lead to losing
some received data from the remote device.
•Start VSP on boot
Inserts the VSP path to the RUN key
(HKEY_LOCAL_MACHINE\SOFTWARE\Microsoft\Windows\CurrentVersion\run) in the
Windows registry. VSP is then started every time Windows starts.
HW VSP –command line parameters
HW VSP can be started with specific parameters on the command line. In this way, it is possible to
create several virtual serial ports simultaneously on one computer. Detailed description of the
parameters can be found at our website: www.HW-group.com.
Example: CharonVirtualCom.exe -R -i192.168.6.21:23 -c5 -S0 -N1 -Nf -Np -H1

I/O Controller 2 Manual
HW group
www.HW-group.com
16/ 42
I/O Controller configuration –Command description
The description of the settings combines WWW-based configuration and TCP/serial setup. Some
functions are only available in serial/TCP setup (TEA security settings, QUIT mode).
I/O Controller status page
Shows an overview of the basic device parameters.

I/O Controller 2 Manual
HW group
www.HW-group.com
17/ 42
Network parameters + TCP Setup Mode

I/O Controller 2 Manual
HW group
www.HW-group.com
18/ 42

I/O Controller 2 Manual
HW group
www.HW-group.com
19/ 42
(IP attempting to access AND N ) = W
Access is granted if the above condition is
true. AND represents bitwise multiplication.
MAC Address 00:0A:59:00:95:6C
MAC address is a unique device address in the Ethernet network and it is always factory-preset. You
can find it on the label inside the device. Using this address, individual devices can be distinguished
for example in the UDP section of the setup program.
The address respects restoring of the default configuration with the “D0” command.
I: Address 192.168.6.15
Configures the IP address of the converter.
J: Port 23
Configures the converter's communication port –
from 1 to 65535.
Port 99 is reserved for TCP Setup, if supported by
the particular model and enabled in the setup.
M: Mask 255.255.255.0
IP network mask applicable in the local network.
Communication with all devices outside of the local
network (as determined by the IP address and
network mask) is directed through the gateway.
G: Gateway 192.168.6.254
Address of the Gateway that enables access to
external networks (outside of the IP range defined
by the converter's IP address and the mask).
====== In IP Setup ======
W: Address 0.0.0.0
IP address of a network or a computer that is allowed to communicate with the device. This value must be
the result of a bitwise AND of the remote IP address and the restriction mask (option N), otherwise the
device does not react.
N: Mask 0.0.0.0
This mask restricts addresses that are allowed to communicate with the device. Security can be
enhanced by setting a fixed address or a suitable restrictive mask that disallows communication with
unauthorized parties.
X: Port 0.0
Y: Port Mask 0.0
Restricts the range of TCP ports that can
communicate with the device.
MASK, IP address and Gateway functions:
An Ethernet device communicates:
•Within a local Ethernet network
No Gateway used or needed. However, IP
addresses of both sides must be within the
configured mask. For example, a mask of
255.255.255.0 means that the IP
addresses can only differ in the last byte.
•Outside of the local network –through
the Gateway, which itself must have an IP
address within the range delimited by the
mask.
In addition to this basic configuration, it is
possible to restrict the range of IP addresses
allowed to communicate with the converter in
“In IP Setup”. For debugging, we therefore
recommend to keep this parameter set to
0.0.0.0.

I/O Controller 2 Manual
HW group
www.HW-group.com
20/ 42
Setting the connection length
Keeping a TCP socket open is
useful when small volumes of
data need to be transferred as
soon as they come in but HW
VSP is not used or a permanent
connection needs to be avoided.
For the duration specified by the B
option, the connection is kept
open and data are sent
immediately, without the delay for
establishing a TCP connection.
On the other hand, a long
timeout means a long period of
inaccessibility through other
sockets (disconnected cable,
TCP setup).
Port configuration in UDP mode
When UDP communication is
used, the remote address must
be specified here.
Otherwise, the communication
will be unidirectional. Data from
the I/O Controller are sent only
to the specified address.
====== Out IP Setup ======
S: Send to IP 192.168.0.252
U: Port 23
If the address in the S option is different from 0.0.0.0, the I/O
Controller works as a Client/Server in the TCP mode. This
means that if no TCP/IP connection is established and the
device either receives serial port data (even a single byte) or
the state of its digital inputs changes (in the range allowed by
the #T option), the device periodically tries to initiate a TCP
connection as a TCP Client. The device remains in the TCP
Server mode in between attempts.
In the UDP mode, the I/O controller sends data from the serial port to this address/port. Control of
digital inputs and outputs in the UDP mode is governed by #E and subsequent parameters.
Set S = 0.0.0.0 to switch the converter to the TCP Server mode.
B: IP Protocol Retry 124
Determines the TCP connection timeout if no communication
takes place. Predefined values are available through the
asterisk notation:
*1: 30 s (n = 35)
*2: 1 min. (n = 45)
*3: 2 min. (n = 63)
*4: 5 min. (n = 77)
*5: 10 min. (n = 101)
*6: 15 min. (n = 124)
*7: 30 min. (n = 144)
*8: 1 h (n = 179)
*9: 2 h (n = 249)
The timeout can be fine-tuned by specifying a value from 10 to
255 according to this formula:
n <16 .. n * 0.2 s
n < 32 .. (n- 15)* 0.8 s + 3.0 s
n < 64 .. (n- 31)* 3.2 s + 15.8 s
n <128 .. (n- 63)*12.8 s + 118.2 s
n <256 .. (n-127)*51.2 s + 937.4 s
Example: B42 => (42-31)*3.2+15.8 = 51s
P: IP Active Call Timer (65535 –Off)