Kolbinger 7521 Series Instructions for use

7521/2/2A/3/4/7 Series
Hardware User’s Manual
7521 Series 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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Table of Contents
1. INTRODUCTION ................................................................................................................................................3
1.1 FEATURES ...............................................................................................................................................................7
1.2 PIN ASSIGNMENT ..................................................................................................................................................11
1.3 SPECIFICATIONS ....................................................................................................................................................23
1.4 BLOCK DIAGRAM..................................................................................................................................................28
1.5 WIRING DIAGRAMS FOR APPLICATIONS ................................................................................................................31
1.6 COMPARISON TABLE.............................................................................................................................................39
1.7 JUMPER SETTINGS .................................................................................................................................................43
2. OPERATION PRINCIPLES.............................................................................................................................44
2.1 SYSTEM MAPPING ................................................................................................................................................44
2.2 HOW TO DEBUG PROGRAMS..................................................................................................................................48
2.3 HOW TO DOWNLOAD PROGRAMS..........................................................................................................................49
2.4 USING THE DOWNLOAD_PORT AS COM PORT .......................................................................................................49
2.5 COM
PORTS COMPARISON....................................................................................................................................50
2.6 THE RS-485 PORT & SELF-TUNER ASIC..............................................................................................................53
2.7 USING THE RED LED & 7-SEG LED DISPLAY.....................................................................................................54
2.8 USING THE RTC & NVSRAM..............................................................................................................................54
2.9 USING EEPROM...................................................................................................................................................55
2.10 USING THE WATCHDOG TIMER .............................................................................................................................55
2.11 USING THE I/O EXPANSION BUS............................................................................................................................56
3. APPLICATIONS.................................................................................................................................................65
3.1 EMBEDDED CONTROLLER .....................................................................................................................................65
3.2 ADDRESSABLE RS-232 PROTOCOL CONVERTER ...................................................................................................66
3.3 LOCAL REAL TIME CONTROLLER..........................................................................................................................67
3.4 REMOTE LOCAL CONTROLLER ..............................................................................................................................68
3.5 I/O EXPANSION FOR PLC APPLICATIONS ..............................................................................................................69
3.6 RADIO MODEM APPLICATIONS..............................................................................................................................70
3.7 USING 4 COM PORT APPLICATION-1....................................................................................................................71

1. Introduction
The 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 7521 series can be ordered as following:
Order Items Module name O. S.
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 7521 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:
 Time-to-market & cost-effective solutions
 Durable, stable, flexible, & easy to program
 Over 50 various I/O modules are supported
 Can be used in harsh, noisy industry environments
However, even though the 7521 series is so versatile, there are some
applications that cannot be initially solved, such as:
 High speed applications
 Special hardware requirement applications
 Special software requirement applications
 A combinations of special hardware & software applications
Therefore, we developed an I/O expansion bus for the 7521 series 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:
 Smaller size compared to parallel devices
 Lower cost compared to parallel devices
 Easier 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:
 7188X+X?? Single module solution a “Customized 7000 Module”
 7000 compatible command sets & RS-485 networking
 Easy hardware/software interface for user to design & manufacture their
own special hardware & software
 Time-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.)
 Durable, stable, flexible, time-to-market & cost-effective total solution.
Some “Customized 7000 Modules” are available as follows:
 IKIT-09: LONG TIME DATA LOGGER=7188XBD+X800
 IKIT-10: LONG TIME 7000 LOGGE=7188XBD+X600
 IKIT-11: ANALOG SIGNAL CONTROLLER=7188XBD+X801
 IKIT-12: Arbitrary Waveform Generator=7188XCD+X300
 More “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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Package List
In addition to this manual, the package includes the following items:
 One 7521 series hardware module
 One hardware manual (this manual)
 One release note
 One software utility disk or CD
 One download cable CA0910F for 7521, 7522, 7523
CA0910 for 7522A, 7524, 7527
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 “7521/7522/7522A/7523/7524/7527 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

1.1 Features
1.1.1 General features
 AMD’s embedded CPU, Am188™ES: 20M or 40M
 SRAM: 128K/256K/512K bytes
 Flash ROM: 256K/512K bytes
 Built-in EEPROM
 Built-in COM port: 2/3/4/5/8 channels
 Isolation voltage on RS-485 port=3000V: 7521/7522/7523
 Industry D/I/O onboard: 7521(D)/7522(D)/7523(D)/
7522A(D)7524(D)/7527(D)
 User defined D/I/O: 7521(D)
 Built-in 5-digit LED display interface
 COM driver support interrupt & 1K QUEUE input buffer
 Built-in I/O expansion bus interface
 Built-in watchdog timer for harsh environments
 Built-in power protection circuit
 Built-in RS-485 network protection circuit
 Built-in self-tuner ASIC controller on RS-485 port
 Program download from PC
 Built-in OS: MiniOS7 of ICP DAS
 Operating temperature: -25°C to +75°C
 Can be used in harsh environments for industry applications
NOTE:
1. ODM wanted
2. “Customized 7000 Modules” wanted
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1.1.2 What is MiniOS7?
The MiniOS7 is an embedded O.S. designed for the 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 752N 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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1.1.3 What is the 64-bit hardware unique serial number?
The 7524/2A/27 equips a 64-bit hardware unique hardware serial number
onboard. This number is unique & cannot be shared by any three 7524/2A/27.
The application software can check this number for illegal copies. It is the most
low cost protection mechanism the 7524/2A/27 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 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 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 1/2/3/4/5/6/7-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
series are designed to act as a “1/2/3/4/5/6/7 port Addressable RS-232
Converter”. The firmware of the 7521 series 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 series can solve
nearly every “Addressable RS-232 Converter” application.
1.1.8 7521 series = Embedded Controller?
The 7521 series is really an embedded controller before downloading any
firmware. After downloading the firmware, the 7521 series acts as an
“Addressable RS-232 Converter”. The 7521/7522/7523 has the 3000V
isolation on the RS-485 port. In almost all areas, the 7521 is equivalent to
the 7188XC+7510. So the 7521 series can be used as an embedded controller
with isolation RS-485 port.
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1.2 Pin Assignment
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Pin assignment of 13-pin screw terminal block(7521/7521D):
Pin Name Description
1 X3 Connects to I/O expansion board
2 X2 Connects to I/O expansion board
3 X1 Connects to I/O expansion board
4 DO3 Digital output, 150mA, 30V
5 DO2 Digital output, 150mA, 30V
6 DO1 Digital output, 150mA, 30V
7 DI3 Digital input, 3.5V ~ 30V
8 DI2 Digital input, 3.5V ~ 30V
9 DI1/
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
1 Data+ DATA+ of RS-485 port
2 TXD Transmits Data (RS-232)
3 RXD Receives Data (RS-232)
4 N/C No Connection
5 GND Signal ground of RS-232
6 N/C No Connection
7 CTS Clear To Send (RS-232)
8 RTS Request To Send (RS-232)
9 Data- 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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Pin assignment of 13-pin screw terminal block(7522/7522D):
Pin Name Description
1 CTS3 Clear To Send of COM3 (RS-232)
2 RTS3 Request To Send of COM3 (RS-232)
3 RXD3 Receives Data of COM3 (RS-232)
4 TXD3 Transmits Data of COM3 (RS-232)
5 GND Signal ground of COM3 & COM4
6 DO1 Digital output, 150mA, 30V
7 DI3 Digital input, 3.5V ~ 30V
8 DI2 Digital input, 3.5V ~ 30V
9 DI1/
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
1 Data+ DATA+ of RS-485 port
2 TXD Transmits Data (RS-232)
3 RXD Receives Data (RS-232)
4 N/C No Connection
5 GND Signal ground of RS-232
6 N/C No Connection
7 CTS Clear To Send (RS-232)
8 RTS Request To Send (RS-232)
9 Data- 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 bottom 14-pin screw terminal block:
Pin Name Description
1 DO 100 mA, 30V max.
2 DI 3.5V ~ 30V
3 D1+ DATA+ pin of COM1 (RS-485)
4 D1- DATA - pin of COM1 (RS-485)
5 CTS1 Clear To Send of COM1 (RS-232)
6 RTS1 Request To Send of COM1 (RS-232)
7 GND Signal ground of RS-232
8 TXD1 Transmits Data of COM1 (RS-232)
9 RXD1 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 14-pin screw terminal block:
15 TXD3+ TXD+ pin of COM3 (RS-422/RS-485)
16 TXD3- TXD - pin of COM3 (RS-422/RS-485)
17 RXD3+ RXD+ pin of COM3 (RS-422)
18 RXD3- RXD - pin of COM3 (RS-422)
19 DI0 Digital Input, 3.5V ~ 30V, channel 0
20 DI1 Digital Input, 3.5V ~ 30V, channel 1
21 DI2 Digital Input, 3.5V ~ 30V, channel 2
22 DI3 Digital Input, 3.5V ~ 30V, channel 3
23 GND GND of Digital Output
24 PWR Power of Digital Output
25 DO0 Digital Output, 100 mA, 30V max., channel 0
26 DO1 Digital Output, 100 mA, 30V max., channel 1
27 DO2 Digital Output, 100 mA, 30V max., channel 2
28 DO3 Digital Output, 100 mA, 30V max., channel 3

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Pin assignment of 13-pin screw terminal block(7523/7523D):
Pin Name Description
1 CTS3 Clear To Send of COM3 (RS-232)
2 RTS3 Request To Send of COM3 (RS-232)
3 RXD3 Receives Data of COM3 (RS-232)
4 TXD3 Transmits Data of COM3 (RS-232)
5 GND Signal ground of COM3 & COM4
6 TXD4 Transmits Data of COM4 (RS-232)
7 RXD4 Receives Data of COM4 (RS-232)
8 DI2 Digital input, 3.5V ~ 30V
9 DI1/
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
1 Data+ DATA+ of RS-485 port
2 TXD Transmits Data (RS-232)
3 RXD Receives Data (RS-232)
4 N/C No Connection
5 GND Signal ground of RS-232
6 N/C No Connection
7 CTS Clear To Send (RS-232)
8 RTS Request To Send (RS-232)
9 Data- 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 bottom 14-pin screw terminal block:
Pin Name Description
1 DO 100 mA, 30V max.
2 DI 3.5V ~ 30V
3 D1+ DATA+ pin of COM1 (RS-485)
4 D1- DATA - pin of COM1 (RS-485)
5 CTS1 Clear To Send of COM1 (RS-232)
6 RTS1 Request To Send of COM1 (RS-232)
7 GND Signal ground of RS-232
8 TXD1 Transmits Data of COM1 (RS-232)
9 RXD1 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 14-pin screw terminal block:
15 CTS3 CTS pin of COM3 (RS-232)
16 RTS3 RTS pin of COM3 (RS-232)
17 TXD3 TXD pin of COM3 (RS-232)
18 RXD3 RXD pin of COM3 (RS-232)
19 GND GND pin of COM3/COM4 (RS-232)
20 CTS4 CTS pin of COM4 (RS-232)
21 RTS4 RTS pin of COM4 (RS-232)
22 TXD4 TXD pin of COM4 (RS-232)
23 RXD4 RXD pin of COM4 (RS-232)
24 GND GND pin of COM4/5 (RS-232)
25 CTS5 CTS pin of COM5 (RS-232)
26 RTS5 RTS pin of COM5 (RS-232)
27 TXD5 TXD pin of COM5 (RS-232)
28 RXD5 RXD pin of COM5 (RS-232)