ICP DAS USA 7188XA User manual

7188XA/B/C & 7521/2/2A/3/4/7 Series Hardware User’ s Manual, Ver. 3.0 Sep/2002, 7Mh-001-20 -----1
7188XA/B/C & 7521/2/2A/3/4/7 Series
Hardware User’s Manual
7000 New Features
1. Self Tuner Inside Your Powerful Tools
2. Multiple Baud Rate
3. Multiple Data Format Create New Ideas
4. Dual WatchDog Inside
5. True Distributed Control Create New Applications
6. High Speed & High Density I/O
Warranty
All products manufactured by ICP DAS are warranted against defective
materials for a period of one year from the date of delivery to the original
purchaser.
Warning
ICP DAS assume no liability for damages consequent to the use of this
product. ICP DAS reserves the right to change this manual at any time without
notice. The information furnished by ICP DAS is believed to be accurate and
reliable. However, no responsibility is assumed by ICP DAS for its use, nor
for any infringements of patents or other rights of third parties resulting from
its use.
Copyright
Copyright 2000 by ICP DAS. All rights are reserved.
Trademark
The names used for identification only may be registered trademarks of their
respective companies.
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7188XA/B/C & 7521/2/2A/3/4/7 Series Hardware User’ s Manual, Ver. 2.0 Sep/2002, 7Mh-001-20 -----2
Table of Contents
1. INTRODUCTION ....................................................................................................................................................... 3
1.1 FEATURES ....................................................................................................................................................................... 7
1.2 PIN ASSIGNMENT..........................................................................................................................................................12
1.3 SPECIFICATIONS ...........................................................................................................................................................30
1.4 BLOCK DIAGRAM .........................................................................................................................................................39
1.5 WIRING DIAGRAMS FOR APPLICATIONS......................................................................................................................43
1.6 COMPARISON TABLE....................................................................................................................................................53
1.7 JUMPER SETTINGS ........................................................................................................................................................58
2. OPERATION PRINCIPLES ...................................................................................................................................60
2.1 SYSTEM MAPPING .......................................................................................................................................................60
2.2 HOW TO DEBUG PROGRAMS ........................................................................................................................................65
2.3 HOW TO DOWNLOAD PROGRAMS................................................................................................................................66
2.4 USING THE DOWNLOAD_PORT AS COM PORT ............................................................................................................66
2.5 COM PORTS COMPARISON ..........................................................................................................................................67
2.6 THE RS-485 PORT & SELF-TUNER ASIC ...................................................................................................................69
2.7 USING THE RED LED & 7-SEG LED DISPLAY..........................................................................................................70
2.8 USING THE RTC & NVSRAM ....................................................................................................................................70
2.9 USING EEPROM..........................................................................................................................................................71
2.10 USING THE WATCHDOG TIMER....................................................................................................................................70
2.11 USING THE I/O EXPANSION BUS ..................................................................................................................................72
3. APPLICATIONS........................................................................................................................................................80
3.1 EMBEDDED CONTROLLER ............................................................................................................................................80
3.2 ADDRESSABLE RS-232 PROTOCOL CONVERTER........................................................................................................82
3.3 LOCAL REAL TIME CONTROLLER................................................................................................................................82
3.4 REMOTE LOCAL CONTROLLER ....................................................................................................................................84
3.5 I/O EXPANSION FOR PLC APPLICATIONS ....................................................................................................................85
3.6 RADIO MODEM APPLICATIONS ....................................................................................................................................86
3.7 USING 4 COM PORT APPLICATION-1..........................................................................................................................87
3.8 USING 4 COM PORT APPLICATION-2..........................................................................................................................88
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7188XA/B/C & 7521/2/2A/3/4/7 Series Hardware User’ s Manual, Ver. 3.0 Sep/2002, 7Mh-001-20 -----3
1. Introduction
The 7188X/7521 series is a series of expandable embedded controllers
designed for industry applications. They can be used to replace the PC or
PLC in harsh environments. The 7188X/7521 series can be ordered as
following:
Order Items Module name O. S.
7188XA(D) Expandable Embedded controller MiniOS7
7188XB(D) Expandable Embedded controller MiniOS7
7188XC(D) Expandable Embedded controller MiniOS7
7521(D) Intelligent Communication Controller
(1 channel of RS-232) MiniOS7
7522(D) Intelligent Communication Controller
(2 channels of RS-232) MiniOS7
7522A(D) Intelligent Communication Controller
(1 channel of RS-232 & 1 channel of RS-422/485) MiniOS7
7523(D) Intelligent Communication Controller
(3 channels of RS-232) MiniOS7
7524(D) Intelligent Communication Controller
(4 channels of RS-232) MiniOS7
7527(D) Intelligent Communication Controller
(7 channels of RS-232) MiniOS7
7XXX 7XXX without 7-SEG display MiniOS7
7XXXD 7XXX with 7-SEG display MiniOS7
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The 7000 series modules have been very successful during the past three
years. Over one hundred thousand modules have been shipped to locations all
over the world. The reasons for our success are given as follows:
lTime-to-market & cost-effective solutions
lDurable, stable, flexible, & easy to program
lOver 50 various I/O modules are supported
lCan be used in harsh, noisy industry environments
However, even though the 7000 family is so versatile, there are some
applications that cannot be initially solved, such as:
lHigh speed applications
lSpecial hardware requirement applications
lSpecial software requirement applications
lA combinations of special hardware & software applications
Therefore, we developed an I/O expansion bus for the 7188X/7521 family
to solve all the above applications above. The I/O expansion bus can be used
to implement various I/O functions such as D/I, D/O, A/D, D/A,
Timer/Counter, UART, flash memory, battery backup SRAM, AsicKey &
other I/O functions. Nearly all kinds of I/O functions can be implemented
by this bus.
The I/O expansion bus includes serial & parallel interface. The parallel
interface is very similar to ISA bus, so the user can move the old ISA bus
design to the I/O expansion bus with very little modification.
Furthermore, the I/O pins of the serial bus are programmable. They can be
programmed as D/I, or D/O. Some pins can be configured to D/I or D/O or
timer input or timer output. There are many serial interface devices today. The
features of these serial devices are given as follows:
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7188XA/B/C & 7521/2/2A/3/4/7 Series Hardware User’ s Manual, Ver. 3.0 Sep/2002, 7Mh-001-20 -----5
lSmaller size compared to parallel devices
lLower cost compared to parallel devices
lEasier to design for isolation applications
The serial interface of the I/O expansion bus can link to these serial
devices very easily. The design of the I/O Expansion Bus makes the idea of a
“Customized 7000 Module” come true. The features of a “Customized 7000
Module” are given as follows:
l7188X+X?? àSingle module solution àa“Customized 7000
Module”
l7000 compatible command sets & RS-485 networking
lEasy hardware/software interface for user to design & manufacture their
own special hardware & software
lTime-to-market ODM solution for user’ s special requirements (any high
speed, complex or combined functions of D/I/O, A/D, D/A,.., etc.)
lDurable, stable, flexible, time-to-market & cost-effective total solution.
Some “Customized 7000 Modules” are available as follows:
lIKIT-09: LONG TIME DATA LOGGER=7188XBD+X800
lIKIT-10: LONG TIME 7000 LOGGE=7188XBD+X600
lIKIT-11: ANALOG SIGNAL CONTROLLER=7188XBD+X801
lIKIT-12: Arbitrary Waveform Generator=7188XCD+X300
lMore “Customized 7000 Modules” will be ready in the near future
Refer to “I/O Expansion Bus in 7188X/7188E User’ s Manual” for more
information.
Refer to “7000 Bus Converter User Manual”chapter 1 for more information
as follows:
1.1 7000 Overview
1.2 7000 Related Documentation
1.3 7000 Common Features
1.4 7000 System Network Configuration
1.5 7000 Dimensions
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7188XA/B/C & 7521/2/2A/3/4/7 Series Hardware User’ s Manual, Ver. 2.0 Sep/2002, 7Mh-001-20 -----6
Package List
In addition to this manual, the package includes the following items:
lOne 7188X/7521 series hardware module
lOne hardware manual (this manual)
lOne release note
lOne software utility disk or CD
lOne download cable àCA0910 for 7188XA, 7188XB
àCA0910F for 7188XC, 7521, 7522, 7523
Note
If any of these items are missing or damaged, contact the local distributors for
more information. Save the shipping materials and cartons in case you want to
ship in the future.
Release Note
It is recommended to read the release note first. All important information will
be given in release note as follows:
•Where the “7188X/7521 Software User’ s Manual” is
•Where the “I/O Expansion Bus for 7188X/7188E User’ s Manual” is
•Where the software driver & diagnostic programs are
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7188XA/B/C & 7521/2/2A/3/4/7 Series Hardware User’ s Manual, Ver. 3.0 Sep/2002, 7Mh-001-20 -----7
1.1 Features
1.1.1 General features
lAMD’ s embedded CPU, Am188™ES: 20M or 40M
lSRAM: 128K/256K/512K bytes
lFlash ROM: 256K/512K bytes
lBuilt-in EEPROM
lBuilt-in RTC&NVRam: 7188XA(D)/7188XB(D)
lBuilt-in COM port: 2/3/4 channels
lIsolation voltage on RS-485 port=3000V: 7188XA(D)/7521(D) series
l64-bit hardware unique serial number inside: 7188XA(D)/7188XB(D)
lIndustry D/I/O onboard: 7188XC(D)/7521(D)/7522(D)/7523(D)
lUser defined D/I/O: 7188XA(D)/7188XB(D)/7188XC(D)/7521(D)
lBuilt-in 5-digit LED display interface
lCOM driver support interrupt & 1K QUEUE input buffer
lBuilt-in I/O expansion bus interface
lBuilt-in watchdog timer for harsh environments
lBuilt-in power protection circuit
lBuilt-in RS-485 network protection circuit
lBuilt-in self-tuner ASIC controller on RS-485 port
lProgram download from PC
lBuilt-in OS: MiniOS7 of ICP DAS
lOperating temperature: -25°C to +75°C
lCan be used in harsh environments for industry applications
NOTE:
1. ODM wanted
2. “Customized 7000 Modules” wanted
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7188XA/B/C & 7521/2/2A/3/4/7 Series Hardware User’ s Manual, Ver. 2.0 Sep/2002, 7Mh-001-20 -----8
1.1.2 What is MiniOS7?
The MiniOS7 is an embedded O.S. designed for the 7188X/7521 series.
Developed by ICP DAS Co. Ltd; It is used to replace the ROMDOS used in
the 7188 series. Several brands of DOS have been created by various
companies. In all cases, DOS--whether PC-DOS, MS-DOS, or ROM-DOS--is
a set of commands or code which tells the computer how to process
information. DOS runs programs, manages files, controls information
processing, directs input and output, and performs many other related
functions. The MiniOS7 provides the equivalent functions of ROMDOS
while, in addition, providing user specific functions for the 7188X/7521
family.
Comparison table between MiniOS7 & ROM-DOS?
MiniOS7 ROMDOS
Power up time 0.1 sec 4 ~ 5 sec
More compact size <64K bytes 64K bytes
Supports I/O expansion bus Yes No
Supports AsicKey Yes No
Flash ROM management Yes No
O.S. update (download) Yes No
Built-in hardware diagnostic functions Yes No
Direct control of the 7000 series modules Yes No
Customer ODM functions Yes No
Free charge Yes No
Note: We reserve the right to change the specifications of MiniOs7
without notice
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7188XA/B/C & 7521/2/2A/3/4/7 Series Hardware User’ s Manual, Ver. 3.0 Sep/2002, 7Mh-001-20 -----9
1.1.3 What is the 64-bit hardware unique serial number?
The 7188XA/7188XB equips a 64-bit hardware unique hardware serial
number onboard. This number is unique & cannot be shared by any two
7188XA/7188XBs. The application software can check this number for illegal
copies. It is the most low cost protection mechanism the 7188XA/7188XB
family currently has
1.1.4 What is the Self-Tuner ASIC?
The 2-wire RS-485 port is designed to directly drive the 7000 series
modules. It is a half-duplex 2-wire RS-485 network. Send/receive directional
control in a 2-wire RS-485 network is very important. Therefore, The
7188X/7521 series equip a Self-Tuner ASIC controller for all RS-485 ports.
The Self-Tuner ASIC controller will auto detect & control the send/receive
direction of the RS-485 network. Consequently, the application program does
not have to worry about the send/receive directional control of the RS-485
network.
1.1.5 What is the I/O Expansion Bus?
The 7188XA, 7188XB, 7188XC & 7521 all support I/O expansion buses. The I/O
expansion bus can be used to implement various I/O functions such as D/I, D/O, A/D,
D/A, Timer/Counter, UART, flash memory, battery backup SRAM, AsicKey & other I/O
functions. Nearly all kinds of I/O functions can be implemented on this bus.
1.1.6 What is the AsicKey?
The I/O expansion bus supports AsicKey. The AsicKey equips a complex
machine for validation checking. Included in this is 128 bytes of private data
for the same purpose. It provides very strong protection against illegal copies.
Every legal user has a unique AsicKey & unique software library, the user can
self check this key, or the software library will check the key automatically. In
this main, it is nearly impossible to remove the AsicKey protection.
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1.1.7 1/2/3-port Addressable RS-232 Converter?
The 4521 is used as an addressable RS-232 converter. It can assign an
address to any RS-232 device in the same RS-485 network. Because the
firmware of the 4521 cannot be modified & the application is different case by
case, many customers complain about the limitations of the 4521. The
7521/7522/7523 are designed to act as a “1/2/3 port Addressable RS-232
Converter”. The firmware of the 7521/7522/7523 can be modified based on
the user’ s special requirements. The onboard industry D/I/O can be used to
control the local devices for emergency conditions. So, the 7521/7522/7523
can solve nearly every “Addressable RS-232 Converter” application.
1.1.8 7188XA/7188XB/7188XC = Addressable RS-232 Converter?
The 7188/7188XA/7188XB/7188XC is designed as an embedded
controller. Therefore, any software can be downloaded into it. If the firmware
for an ”Addressable RS-232 Converter” is downloaded into a
7188/7188XA/7188XB/7188XC, they will act as an “Addressable RS-232
Converter”. Consequently, the most low cost, “Addressable RS-232
Converter” is the 7188XC+ ”Addressable RS-232 Converter Firmware”.
7188XC
The most low cost embedded controller
Addressable
RS-232
Converter
Firmware
The most low cost “Addressable RS
-
232 Converter”
(without isolation on RS-485 port)
+
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7188XA/B/C & 7521/2/2A/3/4/7 Series Hardware User’ s Manual, Ver. 3.0 Sep/2002, 7Mh-001-20 -----
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1.1.9 7521/7522/7523 = Embedded Controller?
The 7521/7522/7523 is really an embedded controller before downloading any
firmware. After downloading the firmware, the 7521/7522/7523 acts as an
“Addressable RS-232 Converter”. The only difference between the 7521 & the
7188XC is the 3000V isolation on the RS-485 port. In almost all areas, the
7521 is equivalent to the 7188XC+7510. So the 7521/7522/7523 can be used
as an embedded controller with isolation RS-485 port.
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7188XA/B/C & 7521/2/2A/3/4/7 Series Hardware User’ s Manual, Ver. 2.0 Sep/2002, 7Mh-001-20 -----
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1.2 Pin Assignment
i-7188XA
Embedded Controller
CPU 80188-40
COM1 : RS-232 / RS-485
COM2 : RS-485, 3000V Isolation
COM3~4 : RS-232
DI:3.5V~30V DO:100mA,30V max
COM4 COM3 COM2
COM1
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Pin assignment of 14-pin screw terminal block(7188XA/7188XAD):
Pin Name Description
1DO1 100mA, 30Vmax.
2DO2 100mA, 30Vmax.
3DI1 3.5V ~ 30V
4DI2 3.5V ~ 30V
5RXD4 RXD pin of COM4 (RS-232)
6TXD4 TXD pin of COM4 (RS-232)
7GND GND pin of COM3 & COM4
8TXD3 TXD pin of COM3 (RS-232)
9RXD3 RXD pin of COM3 (RS-232)
10 INIT* Initial pin
11 D2+ DATA+ pin of COM2 (RS-485)
12 D2-DATA-pin of COM2 (RS-485)
13 +VS V+ of power supply (+10 to +30VDC unregulated)
14 GND GND of power supply
Note: COM3=(TXD3, RXD3, GND), COM4=(TXD4, RXD4, GND),
COM3&COM4 share the same GND-pin(pin 7)
Pin assignment of COM1 connector (DB-9 Male):
Pin Name Description
1DCD Data Carrier Detect (RS-232)
RXD Receives Data (JP1 select RS-232)2
D1+ DATA+ of RS-485 (JP1 select RS-485)
TXD Transmits Data (JP1 select RS-232)3
D1-DATA-of RS-485 (JP1 select RS-485)
4DTR Data Terminal Ready (RS-232)
5GND Signal ground of RS-232
6DSR Data Set Ready (RS-232)
7RTS Request To Send (RS-232)
8CTS Clear To Send (RS-232)
9RI Ring Indicator (RS-232)
Note: The COM1 can be used as a RS-232 or RS-485 port selected by JP1.
Refer to Sec. 1.5 for JP1 settings. If JP1 is set in RS-232, the connector of
COM1 is the same as the DB-9 RS-232 connector of the PC. If JP1 is set in
RS-485, the COM1 can directly drive the 7000 series modules. Refer to Sec.
1.6.6 for wire connections.
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7188XA/B/C & 7521/2/2A/3/4/7 Series Hardware User’ s Manual, Ver. 2.0 Sep/2002, 7Mh-001-20 -----
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i-7188XB
Embedded Controller
CPU 80188-40
COM1 : RS-232 / RS-485
COM2 : RS-485
15~28 : User Define I/O Pin
DI:3.5V~30V DO:100mA,30V max
COM1 COM2
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Pin assignment of bottom 14-pin screw terminal block(7188XB/7188XBD):
Pin Name Description
1DO 100 mA, 30V max.
2DI 3.5V ~ 30V
3D1+ DATA+ pin of COM1 (RS-485)
4D1-DATA-pin of COM1 (RS-485)
5CTS1 Clear To Send of COM1 (RS-232)
6RTS1 Request To Send of COM1 (RS-232)
7GND Signal ground of RS-232
8TXD1 Transmits Data of COM1 (RS-232)
9RXD1 Receives Data of COM1 (RS-232)
10 INIT* Initial pin, 3.5V ~ 30V
11 D2+ DATA+ pin of COM2 (RS-485)
12 D2-DATA-pin of COM2 (RS-485)
13 +VS V+ of power supply (+10 to +30VDC unregulated)
14 GND GND of power supply
Note: The COM1 can be used as a RS-232 port or a RS-485 port. It is not
recommended to use both RS-232 & RS-485 at the same time.
Pin assignment of top 13-pin screw terminal block(7188XB/7188XBD):
15 Pin 15 User defined pin 15
16 Pin 16 User defined pin 16
17 Pin 17 User defined pin 17
18 Pin 18 User defined pin 18
19 Pin 19 User defined pin 19
20 Pin 20 User defined pin 20
21 Pin 21 User defined pin 21
22 Pin 22 User defined pin 22
23 Pin 23 User defined pin 23
24 Pin 24 User defined pin 24
25 Pin 25 User defined pin 25
26 Pin 26 User defined pin 26
27 Pin 27 User defined pin 27
28 Pin 28 User defined pin 28
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Pin assignment of 13-pin screw terminal block(7188XC/7188XCD):
Pin Name Description
1X3 Connects to I/O expansion board
2X2 Connects to I/O expansion board
3X1 Connects to I/O expansion board
4DO3 Digital output, 150mA, 30V
5DO2 Digital output, 150mA, 30V
6DO1 Digital output, 150mA, 30V
7DI3 Digital input, 3.5V ~ 30V
8DI2 Digital input, 3.5V ~ 30V
9DI1/
INIT*
Initial pin or digital input, 3.5V ~ 30V
10 D2+ DATA+ pin of COM2 (RS-485)
11 D2-DATA-pin of COM2 (RS-485)
12 +VS V+ of power supply (+10 to +30VDC unregulated)
13 GND GND of power supply
Pin assignment of COM1 connector (DB-9 Male):
Pin Name Description
1Data+ DATA+ of RS-485 port
2TXD Transmits Data (RS-232)
3RXD Receives Data (RS-232)
4N/C No Connection
5GND Signal ground of RS-232
6N/C No Connection
7CTS Clear To Send (RS-232)
8RTS Request To Send (RS-232)
9Data-DATA-of RS-485 port
Note: The COM1 can be used as a RS-232 port or a RS-485 port. It is not
recommended to use both RS-232 & RS-485 at the same time.
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Pin assignment of 13-pin screw terminal block(7521/7521D):
Pin Name Description
1X3 Connects to I/O expansion board
2X2 Connects to I/O expansion board
3X1 Connects to I/O expansion board
4DO3 Digital output, 150mA, 30V
5DO2 Digital output, 150mA, 30V
6DO1 Digital output, 150mA, 30V
7DI3 Digital input, 3.5V ~ 30V
8DI2 Digital input, 3.5V ~ 30V
9DI1/
INIT*
Initial pin or digital input, 3.5V ~ 30V
10 D2+ DATA+ pin of COM2 (RS-485)
11 D2-DATA-pin of COM2 (RS-485)
12 +VS V+ of power supply (+10 to +30VDC unregulated)
13 GND GND of power supply
Pin assignment of COM1 connector (DB-9 Male):
Pin Name Description
1Data+ DATA+ of RS-485 port
2TXD Transmits Data (RS-232)
3RXD Receives Data (RS-232)
4N/C No Connection
5GND Signal ground of RS-232
6N/C No Connection
7CTS Clear To Send (RS-232)
8RTS Request To Send (RS-232)
9Data-DATA-of RS-485 port
Note: The COM1 can be used as s RS-232 port or s RS-485 port. It is not
recommended to use both RS-232 & RS-485 at the same time.
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