IPCOMM IPC191V2 WIN User manual

General
Operating, Maintenance and
Installation Manual
Hardware Platform
Protocol Converter
- Windows Version -
“Industrial PC IPC191V2 WIN”
Gundstraße 15 Edition December 2007
D-91056 Erlangen Version 1.0.1
Phone: [phone]
Fax: [phone]
Internet: http://www.ipcomm.de
Email: [e-mail]
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Index
.............................................................................................................................. 11INTRODUCTION
.......................................................................................................... 22HARDWARE DESCRIPTION
.................................................................................................................................... 22.1 GENERAL
........................................................................................................... 32.2 HARDWARE COMPONENTS
.......................................................................................................................... 32.2.1 Mainboard
......................................................................................... 42.2.2 CPU-Module RS232 Interfaces
................................................................................................................ 52.2.3 Hardlock Dongle
...... 52.2.4 8-Port RS232 Communication Board (RS232 Interfaces for remote communication)
............................................................................................................ 52.2.5 Ethernet Interfaces
.................................................................................................................... 62.2.6 CompactFlash
....................................................................................................... 62.2.7 CMOS Lithium Battery
........................................................................................................................... 72.2.8 CPU LED
..................................................................................................................... 82.2.9 Power Supply
....................................................................................................................... 93BACKUP, RESTORE
................................................................................................. 93.1 RESTORATION /REINSTALLATION
...................................................................................................................................... 93.2 BACKUP
................................................................................................... 104INTERFACE CONFIGURATION
.................................................................................................................................. 104.1 MODEL A
.................................................................................................................................. 114.2 MODEL C
.................................................................................................................................. 114.3 MODEL B
............................................................................ FEHLER!TEXTMARKE NICHT DEFINIERT.4.4 MODEL L
.................................................................................................................................. 124.5 MODEL D
........................................................................................................................ 135TECHNICAL DATA
..................................................................................................................................... 146APPENDIX
............................................................................................................ 156.1 IPC191 CAD DRAWING
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Subject to alterations Version 1.0.1
IPCOMM GmbH - 1 - IPC191 V2 WIN Manual
Gundstraße 15 Copyright © 2007 IPCOMM GmbH
D-91056 Erlangen All rights reserved
1 Introduction
All technical information, descriptions and illustrations contained in this Operating, Maintenance and
Installation Manual remain our property and shall not be used otherwise than for operating this
System, nor shall they be copied, reproduced or passed on to third parties or brought to their notice
without our prior written consent.
The information represented in this manual is in keeping with current standards and is subject to later
alterations.
This manual contains important instructions referring to safe installation, commissioning, operation
and maintenance.
Read this manual carefully before starting up the protocol converter and observe the instructions.
In order to comply with the guidelines for electro-magnetic compatibility in industrial PCs (or other
variants) only CE-certified components are used in compliance with project-specific requirements.
It is to be noted that the Protocol Converter (IPC191) has not been protected against lightning and the
operator should, if desired, take appropriate protective precautions.
All trademarks and brand names contained in this user manual are for identification purposes only and
can be owned by their respective holders.
Finally we want to draw your attention to the fact that any warranties with respect to delivered goods
will be invalid in the event that:
•Operation, servicing and maintenance are not carried out accurately according to the
instructions, repairs are not carried out by our personnel or without our prior written consent.
•Commissioning is not carried out by our personnel or we have not given our approval for the
commissioning or the commissioning is carried out by untrained personnel.
•The unit is used inadequately, incorrectly, negligently or inappropriately or for a purpose other
than that originally intended.
•The serial number is removed from the product.
For your protection, observe the following safety precautions when setting up your equipment:
•Follow all cautions and instructions marked on the equipment.
•Ensure that the voltage and frequency of your power source match the voltage and frequency
inscribed on the equipment's electrical rating label.
•Never push objects of any kind through openings in the equipment. Dangerous voltages may
be present. Conductive foreign objects could produce a short circuit that could cause fire,
electric shock, or damage to your equipment.
All in this Document used Trade marks are stated for identification purposes and may be the
property of the various holders.
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2 Hardware Description
2.1 General
As hardware platform for the protocol converter a 19” industrial PC is used.
This solution offers a high degree on flexibility, performance and reliability.
Mounting and intensive tests of the industrial PC are done in our company.
Before and after a 48 hour Burn-in Test each device must run through a
complete function test
All components are cooled passively. Only if critical system temperatures
have been reached two independent housing fans are switched on
automatically. Important for the selection of our components are particularly
items like quality, availability and a high durability.
The industrial PC consists of a 19“ chassis (1U) with an integrated Dual PCI
riser card for inserting the appropriate cards.
The mains power supply is 90 – 264 V AC, 127 – 373 V DC autorange,
optional 10 – 30 V DC power supply (other on request).
S/N, Model, Voltage
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Figure 1. Front view Industrial PC
Power
Button
Power
LED
Com
p
actFlash Card
DVD-RW Drive
CPU LED COM 2
Port
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On the figure 2 you can see the reverse side of our Industrial PC. The pin
assignments vary according to execution. Overview of the different models is
to be found under 3. Interface Configuration.
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Figure 2. Overview Interfaces
2.2 Hardware Components
2.2.1 Mainboard
The Mini-ITX Mainboard is an ultra compact x86 dual LAN platform with all the
necessary interfaces. Its heart consists of a fanless highly efficient embedded
VIA Eden processor. The mainboard provides one DIMM slot for DDR
memory modules and supports up to 1GB system memory.
The following interfaces are provided by the CPU module:
•2 x RS232 Interface (model-specific)
•2 x RJ45 LAN Interface
•Bi-directional Parallel Port
•EIDE Interface
•VGA Interface
•Keyboard- / Mouse Port
Monitor LAN
Keyboard
LAN
COM 1
Main Power
Supply input
PCI 2
PCI 1
e.g.: COM 4 – COM 11
8 Port DB 9 Male connector
cable
(Optional: DB25 (Male, Female) )
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2.2.2 CPU-Module RS232 Interfaces
The installed mainboard provides 3 serial interfaces. However, depending on
the model these interfaces are completely or only partly available at the
chassis. COM 2 – COM 3 do not possess an RI signal.
The signal level of the serial interfaces can be changed between 5 and 12 V
by means of a jumper. COM3 interface is reserved for internal purpose and
can not be used.
This interface type is used for COM 1
SERIAL PORT Pin Direction Description
RS232 DTE
DB9 male connector 1 INPUT DCD Data Carrier Detect
2 INPUT RXD Receive Data
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3 OUTPUT TXD Transmit Data
4 OUTPUT DTR Data Terminal Ready
5 GND Ground
6 INPUT DSR Data Set Ready
7 OUTPUT RTS Request To Send
8 INPUT CTS Clear To Send
9 INPUT RI Ring Indicator
Figure 3. Pin Assignment of DB9 Interface (Computer) COM1
This interface type is used for COM 2 – COM 4
SERIAL PORT Pin Direction Description
RS232 DTE
DB9 male connector 1 INPUT DCD Data Carrier Detect
2 INPUT RXD Receive Data
3 OUTPUT TXD Transmit Data
4 OUTPUT DTR Data Terminal Ready
5 GND Ground
6 INPUT DSR Data Set Ready
7 OUTPUT RTS Request To Send
8 INPUT CTS Clear To Send
9
Figure 4. Pin Assignment of DB9 Interface (Computer) COM2 – COM4
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2.2.3 Hardlock Dongle
The hardlock dongle is a hardware protection for the software. It must be
attached onto the parallel interface. Without hardlock dongle the software
does not boot!
Figure 5. Hardlock Dongle
2.2.4 8-Port RS232 Communication Board (RS232 Interfaces for
remote communication)
Each IPC191 can be equipped with up to two serial interface cards.
SERIAL PORT Pin Direction Description
RS232 DTE
DB9 male connector 1 INPUT DCD Data Carrier Detect
2 INPUT RXD Receive Data
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3 OUTPUT TXD Transmit Data
4 OUTPUT DTR Data Terminal Ready
5 GND Ground
6 INPUT DSR Data Set Ready
7 OUTPUT RTS Request To Send
8 INPUT CTS Clear To Send
9
Figure 6. Pin Assignment of DB9 interface (Communication Board)
2.2.5 Ethernet Interfaces
The industrial PC features up to two Ethernet Interfaces generally. The
connection is set up via a 10/100 Mbps BaseT (RJ45) interface. Further
Interfaces with 10/100 Mbps or 10/100/1000 Mbps BaseT are possible on
request.
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2.2.6 CompactFlash
The CompactFlash card serves as a mass storage device, i.e. for storing the
operating system, the applications and configuration data. As a result the
disadvantages involved with the use of a rotating harddisk are avoided, thus
improving the reliability of the system substantially since a CompactFlash has
an MTBF of at least 4,000,000 hours.
The CompactFlash adapter is simply connected to the IDE bus of the CPU
module and treated just like a hard disk.
Push to take
CompactFlash
out
Figure 7. CompactFlash Adapter
With the power supply switched off the CompactFlash card can simply be
taken out or inserted enabling a quick change to different hardware.
2.2.7 CMOS Lithium Battery
The onboard CMOS RAM stores system configuration data and has an
onboard battery power supply. The long-life Lithium battery has normally a
lifetime of at least 5 years.
If the CMOS battery is empty and the CMOS information has been deleted,
the CMOS-RAM is programmed by the BIOS with default settings.
The converter can be operated faultlessly even if the CMOS RAM is not
provided by the battery. After the battery has been changed only time and
date must be input.
For opening the case 3 screws on the top must be removed. The battery
holder is soldered in the Mainboard and well visible. Attention: Open-frame
power supplies are used. Because of this, the process should be carried out
only by experienced electronic engineers. The device must be completely
disconnected from any power supply. Before opening please push the power
button (without electricity supply) several times to eliminate residual voltages
of the power supply.
Battery replacement must be carried out by qualified specialists. CAUTION!
Incorrect replacement might cause the danger of explosion. Replace the
battery exclusively by the same type (3 V DC, CR2032). Used batteries are to
be disposed absolutely in accordance with the manufacturer's instructions.
Please pay attention to the correct polarity!
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2.2.8 CPU LED
The CPU LED shows the states of conversion software and operating system.
Following figure shows all possible indications:
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Figure 8. CPU-LED indications
ON
Passive
Mode 0,5
(Standby)
OFF
Active 0,5 5 s
Mode
ON
OFF
ON
Software has
stopped
OFF
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2.2.9 Power Supply
Power supplies with different input voltages can be used in the IPC191.
Please pay attention to the correct polarity and input voltage.
2.2.9.1 AC Power Supply
By using AC voltages a specific power supply cable (Fig. 8) is supplied.
Please use this cable exclusively.
Figure 9. Power Cable
2.2.9.2 DC Power Supply
By using DC voltages only a male connector is supplied. This connector has
to be used. By connecting the cable with the male connector the correct
polarity must be kept. The wire cross-section must be at least 1,5 mm².
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Figure 10. DC Power Connection socket
Power Supply
Input
-
Connection
for Earth
Potential
Power Supply
Input
+
DC Power Cable
(Example, not
included in
delivery)
Label for correct
Power Voltage
(e. g. 24 V)
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3 Backup, Restore
The operating system Windows XP, the protocol conversion software ipConv and the backup software
“Acronis True Image” are preinstalled at the IPC191. For saving space on the CompactFlash only
necessary components have been installed. The access to the CompactFlash has been minimized by
system optimizing.
3.1 Restoration / Reinstallation
If the origin state of the system shall be restored the provided CD / DVD created by “Acronis True
Image” is necessary.
The CD / DVD was created before delivery and includes Windows XP, Acronis True Image and the
ipConv software.
The following steps are necessary for the system restoration:
1. So far as possible, backup your configuration data and the software (if these are more current
than the delivered one).
2. Insert Acronis True Image Backup CD / DVD in your CD / DVD drive.
3. Please, reboot the system. The System boots from CD / DVD drive and the True Image boot
menu appears.
.Please, select the option „One - Click Restore “.4
lease, note that all data on the CompactFlash are erased with this process.
P
3.2 Backup
Backup of software and configuration is described in the “ipConv documentation”.
For generating a backup of the entire system (CompactFlash) please use the preinstalled backup
software “Acronis True Image”. The image files can be stored on CD, DVD or USB mass storage
evices..
d
Further information of the backup software is described in the attached documentation
belonging to the Acronis True Image software.
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4 Interface Configuration
The following tables represent the configuration of the individual interfaces of
miscellaneous models. The setting is carried out either in the BIOS or via
jumpers on the appropriate card depending on the unit. The allocation
diagram of the link can be found in the documentation of the component.
4.1 Model A
Assembly Device I/O port IRQ Label Connector
Mainboard ser1 3F8 4
IOIOI (Chassis
rear) DB9ST
ser2 2F8 3
IOIOI (Chassis
front) DB9ST
ser3 3E8 5 CPU (Diagnose) NOT Connected
en1 PCI PCI LAN1 RJ45
en2 PCI PCI LAN2 RJ45
UART 1 ser4 PCI PCI COM4 DB9ST
ser5 PCI PCI COM5 DB9ST
ser6 PCI PCI COM6 DB9ST
ser7 PCI PCI COM7 DB9ST
ser8 PCI PCI COM8 DB9ST
ser9 PCI PCI COM9 DB9ST
ser10 PCI PCI COM10 DB9ST
ser11 PCI PCI COM11 DB9ST
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4.2 Model B
Assembly Device I/O port IRQ Label Connector
Mainboard ser1 3F8 4
IOIOI (Chassis
rear) DB9ST
ser2 2F8 3
IOIOI (Chassis
front) DB9ST
ser3 3E8 5 CPU (Diagnose) NOT Connected
en1 PCI PCI LAN1 RJ45
en2 PCI PCI LAN2 RJ45
UART 1 ser4 PCI PCI COM4 DB9ST
ser5 PCI PCI COM5 DB9ST
ser6 PCI PCI COM6 DB9ST
ser7 PCI PCI COM7 DB9ST
ser8 PCI PCI COM8 DB9ST
ser9 PCI PCI COM9 DB9ST
ser10 PCI PCI COM10 DB9ST
ser11 PCI PCI COM11 DB9ST
UART 2 ser12 PCI PCI COM4 DB9ST
ser13 PCI PCI COM5 DB9ST
ser14 PCI PCI COM6 DB9ST
ser15 PCI PCI COM7 DB9ST
ser16 PCI PCI COM8 DB9ST
ser17 PCI PCI COM9 DB9ST
ser18 PCI PCI COM10 DB9ST
ser19 PCI PCI COM11 DB9ST
4.3 Model C
Assembly Device I/O port IRQ Label Connector
Mainboard ser1 3F8 4
IOIOI (Chassis
rear) DB9ST
ser2 2F8 3
IOIOI (Chassis
front) DB9ST
ser3 3E8 5 CPU (Diagnose) NOT Connected
en1 PCI PCI LAN1 RJ45
en2 PCI PCI LAN2 RJ45
Ethernet
10/100
BaseT en3 PCI PCI LAN3 RJ45
UART 1 ser4 PCI PCI COM4 DB9ST
ser5 PCI PCI COM5 DB9ST
ser6 PCI PCI COM6 DB9ST
ser7 PCI PCI COM7 DB9ST
ser8 PCI PCI COM8 DB9ST
ser9 PCI PCI COM9 DB9ST
ser10 PCI PCI COM10 DB9ST
ser11 PCI PCI COM11 DB9ST
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4.4 Model D
Assembly Device I/O port IRQ Label Connector
Mainboard ser1 3F8 4
IOIOI (Chassis
rear) DB9ST
ser2 2F8 3
IOIOI (Chassis
front) DB9ST
ser3 3E8 5 CPU (Diagnose) NOT Connected
en1 PCI PCI LAN1 RJ45
en2 PCI PCI LAN2 RJ45
USART 1 ser4 PCI PCI COM4 DB25ST
4.5 Model E
Assembly Device I/O port IRQ Label Connector
Mainboard ser1 3F8 4
IOIOI (Chassis
rear) DB9ST
ser2 2F8 3
IOIOI (Chassis
front) DB9ST
ser3 3E8 5 CPU (Diagnose) NOT Connected
en1 PCI PCI LAN1 RJ45
en2 PCI PCI LAN2 RJ45
en3 PCI PCI LAN3 RJ45
en4 PCI PCI LAN4 RJ45
4.6 Model L
Assembly Device I/O port IRQ Label Connector
Mainboard ser1 3F8 4
IOIOI (Chassis
rear) DB9ST
ser2 2F8 3
IOIOI (Chassis
front) DB9ST
ser3 3E8 5 CPU (Diagnose) NOT Connected
en1 PCI PCI LAN1 RJ45
en2 PCI PCI LAN2 RJ45
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5 Technical Data
Chassis
•19“ rack mount chassis (1U)
•Dual PCI riser card
•Excellent air flow for maximum heat dissipation
Power Supply
•Fanless
•90 – 264 V AC, 127 – 373 V DC autorange, optional 24 V DC,
further voltages on request
•Power consumption: max. 50 W (depending on the used type)
•CE/TÜV certified
Mainboard
•VIA Eden processor 600 MHz CPU
•Max 1 GB DDR RAM
•EIDE hard disk and flash disk drive interface
•Digital I/O Interface
•2 x high speed serial ports
•Bi-directional parallel port
•Real-time clock/calendar
•2 x RJ45 10/100BaseT LAN interface onboard
Serial Cards
•Up to sixteen serial RS232 ports
•DB9 male connectors, optional DB25 (Male, Female)
•50 bps to 921.6Kbps transmission speed
•16KV ESD Protection
Mass Storage
•Rugged CompactFlash, Industrial – Grade
•Removable flash card
•No Moving Parts
•64 MB, max. 4 GB supported
•Vibration: 15 G peak to peak max.
•Shock: 1000 G max.
•MTBF ≥4.000.000 hours
Video
•Standard VGA graphic adapter
General
•All components are CE certified
•Height: 1 U
•Dimension (W x H x D): 19" x 1.75" x 15"
(482.6 mm x 44.45 mm x 381 mm)
•Weight: 5,80 kg
Operating
Environment
•Operating Temperature: 0° C to 45° C
•Storage Temperature: 0° C to 60° C
•Relative Humidity (non condensing): 5 % to 90 %
Assembled by IPCOMM GmbH/Germany
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6 Appendix
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