Moxa Technologies TCC-100 Series User manual

Moxa TCC-100/100I User’s Guide
Seventh Edition, June 2008
www.moxa.com/product
©2008 Moxa Inc., all rights reserved.
Reproduction without permission is prohibited.

Moxa TCC-100/100I User’s Guide
The software described in this manual is furnished under a license agreement and
may be used only in accordance with the terms of that agreement.
Copyright Notice
Copyright ©2008 Moxa Inc.
All rights reserved.
Reproduction without permission is prohibited.
Trademarks
MOXA is a registered trademark of Moxa Inc.
All other trademarks or registered marks in this manual belong to their respective
manufacturers.
Disclaimer
Information in this document is subject to change without notice and does not
represent a commitment on the part of Moxa.
Moxa provides this document “as is,” without warranty of any kind, either
expressed or implied, including, but not limited to, its particular purpose. Moxa
reserves the right to make improvements and/or changes to this manual, or to the
products and/or the programs described in this manual, at any time.
Information provided in this manual is intended to be accurate and reliable.
However, Moxa assumes no responsibility for its use, or for any infringements on
the rights of third parties that may result from its use.
This product might include unintentional technical or typographical errors.
Changes are periodically made to the information herein to correct such errors,
and these changes are incorporated into new editions of the publication.

Technical Support Contact Information
www.moxa.com/support
Moxa Americas:
Toll-free: 1-888-669-2872
Tel: [phone]
Fax: [phone]
Moxa China (Shanghai office):
Toll-free: 800-820-5036
Tel: [phone]
Fax: [phone]
Moxa Europe:
Tel: [phone]
Fax: [phone]
Moxa Asia-Pacific:
Tel: [phone]
Fax: [phone]

Table of Contents
Chapter 1 Introduction...........................................1-1
Overview.............................................................. 1-2
Product Features................................................... 1-4
Package Checklist................................................. 1-4
Product Specifications.......................................... 1-4
Schematic............................................................. 1-6
LED Indicators..................................................... 1-6
Chapter 2 Installation.............................................2-1
Hardware Installation ........................................... 2-2
Termination Resistor Diagram.............................. 2-7
Function Diagram................................................. 2-7
Isolation Block Diagram....................................... 2-8
Typical Applications............................................. 2-8
Appendix A Service Information............................. A-1
Moxa Internet Services.........................................A-2
Problem Report Form...........................................A-3
Product Return Procedure.....................................A-4
Revision History...................................................A-5

1
1
Chapter 1 Introduction
TCC-100/100I is an RS-232 to RS-422/485 media converter. Note that TCC-100I
comes with 2 KV isolation protection.
The following topics are covered in this chapter:
Overview
Product Features
Package Checklist
Product Specifications
Schematic
LED Indicators

Moxa TCC-100/100I User’s Guide
Overview
Introduction
Many important devices used in today’s industrial environment are still designed
for use with an RS-232 interface. The reason is due in part to tradition, and in part
to convenience. RS-232 hardware is relatively easy to design, and the device can
be readily connected to most PCs. The drawback is that RS-232 is a point-to-point
interface, and it imposes a distance limitation of only 15 meters between the
device and the computer.
To overcome these limitations, many users employ RS-232 to RS-422/485
converters, allowing RS-232 devices to connect to an industrial RS-422 or
RS-485 network and transmit data over distances up to 1.2 km. The RS-422/485
standards overcome the distance limitation by using a differential signal for
transmitting data and control signals. Transmission distance and multi-drop
connections are not the only issues of importance for industrial applications In
addition, housing, wiring, power supply, and over-surge protection are also
serious concerns.
TCC-100I provides isolation protection for users who need an industrial grade
interface conversion product to extend RS-232 transmission distance and increase
networking capability. Its superior industrial application design, which includes
DIN-Rail mounting, terminal block wiring, external terminal block power, and
optical isolation for system protection, makes TCC-100I suitable for use in
critical industrial environments. Simply put, your RS-232 devices can be used as
part of an industrial RS-422/485 network, but without any hardware or software
changes.
1-2

Introduction
RTS/CTS RS-422 Handshaking Signals
TCC-100/100I provides RS-422 handshaking signal support. The RTS and CTS
signals help solve the RS-422 signal handshaking problem and reduce data
transmission errors.
Built-in RS-485 ADDC™ Intelligence
ADDC™ (Automatic Data Direction Control), a Moxa leading technology, uses a
clever hardware solution to manage RS-485’s data flow control problem.
ADDC™ is a hardware data flow solution that automatically senses and controls
data direction, making the handshaking signal method obsolete.
Isolation
Moxa’s electrical isolation technology uses two photo couplers to create a gap in
each electrical signal. One photo coupler transforms the electrical signal into a
light signal, which is transmitted across a small gap, and then the other photo
coupler transforms the light back into an electrical signal. In this way, the two
electrical circuits are completely isolated from each other, limiting the damage
that could otherwise be caused by power surges in the electrical signal.
Reverse Power Protection
The Reverse Power Protection feature provides extra protection against
accidentally connecting the power cables to the wrong terminal. The converter is
designed to automatically detect which power wire is positive and which is
negative, and then adjust the power supply accordingly.
DIP Switch Selectable Terminator
For many products of this type, the termination resistor is set by a jumper located
inside the product’s casing, so that the user must open the casing to disable or
change the resistor’s strength. Moxa offers a better solution. TCC-100/100I’s
terminator is set with a DIP Switch located on the outside of the converter’s
casing.
Auto Baud Rate Detection
TCC-100/100I incorporates a method for automatically detecting the serial
signal’s baud rate by hardware. This is an extremely convenient feature for the
user. Even if a device’s baud rate changes, the signal will still be transmitted
through the RS-232 to RS-422/488 converter without any problem.
1-3

Moxa TCC-100/100I User’s Guide
Product Features
•RS-232 to RS-422 conversion with RTC/CTS support
•RS-232 to 2/4-wire RS-485 conversion
•Detachable wall and DIN-Rail mounting for easy RS-422/485 wiring
•PWR, Tx, and Rx LEDs
•16 KV ESD Surge Protection
•2 KV Isolation (TCC-100I) for both power and RS-422/485 signals
•Operating temperature from -20°C to 60°C
Package Checklist
Before installing Moxa TCC-100/100I, verify that the package contains the
following items:
•TCC-100 or TCC-100I
•User’s Manual (this document)
•Warranty Booklet
Please notify your sales representative if any of the above items is missing or
damaged.
Product Specifications
Model Names TCC-100, TCC-100I
Communication
RS-232 Signal Supports Tx, Rx, DTR, DSR, RTS, CTS, DCD;
Female DB9 interface
RS-422/485 Signal Terminal Block connector (DIP Switch selectable)
4-wire RS-422 (with RTS/CTS), up to 10 nodes (1.2
km)
4-wire RS-485: up to 32 nodes (1.2 km)
2-wire RS-485: up to 32 nodes (1.2 km)
RS-485 Data Direction
Control ADDC™
Baud Rate 50 bps to 230.4 Kbps
Surge Protection 16 KV ESD RMS, for all signals
Isolation 2 KV (TCC-100I) for both Power and Signal
Environment
Operating Temperature -20 to 60°C (-4 to 140°F)
1-4

Introduction
Storage Temperature -20 to 85°C (-4 to 185°F)
Humidity 5 to 95 %RH
Power
Input Power Voltage External Power 12-30 VDC, Terminal Block
Reverse Power
Protection Protects against V+/V- reversal
Over Current Protection Protects against 2 signals shorted together
Power Consumption 400 mA(max.) at 12V
Mechanical
Dimensions
(W ×D ×H) 67 ×100 ×22 mm (without DIN-Rail mounting kit)
90 ×100 ×22 mm (with DIN-Rail mounting kit)
Case Aluminum
Plug-In Screw Terminal
Block #22 – #16 AWG
Weight 148±5 g
Regulatory Approvals CE, FCC (Class B)
WARNING 1. This unit is not meant to be sold to consumers. It will only
be shipped to manufacturers of factories.
2. The DC source should come from an external adapter or
12 to 48 VDC source (not from DC mains) by using a
transfer device.
3. This unit should be installed or set up by a qualified
service person.
1-5

Moxa TCC-100/100I User’s Guide
1-6
Schematic
11.5 mm 67 mm
28.7 mm
43 mm
28.7 mm
100.4 mm
O4
O7
O3.5
22 mm
LED Indicators
TCC-100/100I’s top panel contains three LED
indicators, as described in the following table:
LED Name LED Function
PWR Red indicates the power is on.
Green indicates TCC-100/100I is
receiving data from the RS-232
port.
Yellow indicates TCC-100/100I
is receiving data from the
RS-422/485 port.
PWR
RED
GREEN
YELLOW

2
2
Chapter 2 Installation
This chapter includes information about how to install TCC-100/100I, as well as
function and block diagrams.
The following topics are covered in this chapter:
Hardware Installation
Termination Resistor Diagram
Function Diagram
Isolation Block Diagram
Typical Applications

Moxa TCC-100/100I User’s Guide
Hardware Installation
Installing TCC-100/100I involves five straightforward steps:
•STEP 1: Set the DIP Switches
•STEP 2: Attach the Power Supply
•STEP 3: Wire the Terminal Block
•STEP 4: Attach the RS-232 Converter
•STEP 5: Test the Connection
The details of each of these five steps are described next.
STEP 1: Set the DIP Switches
The DIP Switches on TCC100/100I are used to set the signal transmission mode
and enable or disable the termination resistor. You can configure for either
RS-422 or RS-485 transmission mode. Your program and serial port should be set
to match the converter’s settings.
SW1—Switch 1 selects RS-422 or RS-485 mode. The default is “On” for RS-422
mode.
SW2—Switch 2 selects 2-wire or 4-wire RS-485 mode. The default is “On” for
4-wire RS-485. Note that if Switch 1 is set to RS-422 mode, then Switch 2
is inactive.
SW3—Switch 3 enables the terminator to 120 Ohms. When enabled, the 120
Ohm resistor prevents signal reflection during RS-485 transmission. The
default is “On” to enable the terminator. If your particular application does
not require using the termination resistor, then simply set Switch 3 to the
off position to disable it.
2-2

Installation
2-3
Dip Switch Settings
SW1 SW2 SW3
RS-422 Terminator active ON ON ON
123
SW1 SW2 SW3
RS-422 ON ON OFF
123
SW1 SW2 SW3
4-wire RS-485 Terminator
active OFF ON ON
123
SW1 SW2 SW3
4-wire RS-485 OFF ON OFF
123
SW1 SW2 SW3
2-wire RS-485 with
Terminator OFF OFF ON
123
SW1 SW2 SW3
2-wire RS-485 OFF OFF OFF
123

Moxa TCC-100/100I User’s Guide
The newly implemented DIP-2 Switches are used to configure the pull high/low
resistors for different applications.
Pull High/Low Resistor DIP-2 SW1 DIP-2 SW2
150K (default) OFF OFF
1K ON ON
NOTE We recommend setting the pull high/low resistor to 1K (ON/ON)
when termination is enabled.
2-4

Installation
2-5
STEP 2: Attach the Power Supply
V+ V
-
+
-
Power Supply
12 - 30 VDC
TCC-100/100I is powered by an
external 12-30 VDC power supply. To
connect the power supply, run two
wires from the V+ and V- terminals on
TCC’s 3-connector terminal block to
the DC power supply, as shown in the
figure. Once the power supply is
connected to its power source, the
PWR LED located on TCC’s top panel
should become illuminated in red.
NOTE: TCC-100/100I provides reverse power protection. I.e., it will
automatically detect which power wire is negative, and which is positive.
STEP 3: Wire the Terminal Block
There are three wiring options available for connecting to TCC-100/100I’s
RS-422/485 terminal block.
Data +
Data -
Tx+(B)
RTS+(B)
RTS-(A)
CTS+(B)
CTS-(A)
SGND
Tx-(A)
Rx+(B)(Data+)
Rx-(A)(Data-)
SGND
2-wire RS-485
When using the 2-wire RS-485 wiring option,
connect three wires from TCC-100/100I’s
terminal block to the opposite connection.As
shown in the figure, connect from Data+ to
Data+, from Data- to Data-, and from SGND
to SGND.
Tx+(B)
RTS+(B)
RTS
- (A)
CTS+(B)
CTS
- (A)
SGND
Tx
- (A)
Rx+(B)(Data+)
Rx
- (A)(Data - )
Rx+
Rx
-
Tx+
Tx
-
SGND
4-wire RS-485
When using the 4-wire RS-485 wiring
option, connect five wires from
TCC-100/100I’s terminal block to the
opposite connection. As shown in the figure,
connect from Tx+(B) to Rx+, from Tx-(A)
to Rx-, from Rx+(B) to Tx+, from Rx-(A) to
Tx-, and from SGND to SGND.

Moxa TCC-100/100I User’s Guide
RS-422
When using the RS-422 wiring option, first
follow the 4-wire RS-485 wiring instructions
given above.
Optional RTS/CTS Handshaking Signals
If your software is set up to send and receive
RTS/CTS signals over separate wires, you
should also connect from RTS+(B) to CTS+,
from RTS-(A) to CTS-, from CTS+(B) to
RTS+, and from CTS-(A) to RTS-.
Tx+(B)
RTS+(B)
RTS-(A)
CTS+(B)
CTS-(A)
SGND
Tx-(A)
Rx+(B)(Data+)
Rx-(A)(Data-)
Rx+
CTS+
CTS-
RTS+
RTS-
SGND
Rx-
Tx+
Tx-
Optiona
l
STEP 4: Attach the RS-232
Connector
Depending on your application,
use the appropriate serial cable to
connect from CC-100/100I’s
RS-232 Female DB9 port to your
RS-232 device, or to your
computer’s COM port.
5 4 3 2 1
9 8 7 6
Female DB9 PIN RS-232
1 DCD
2 TxD
3 RxD
4 DSR
5 GND
6 DTR
7 CTS
8 RTS
9 ---
RS-232 Pin Assignment Diagram
STEP 5: Test the Connection
After setting the DIP Switches, connecting the power, wiring the terminal block,
and attaching the RS-232 connector, we suggest using a Console Terminal
program, such as HyperTerminal or Moxa Terminal Emulator, to test the
connection. If you have an RS-422/485 serial board (such as Moxa CP-132, a
2-port RS-422/485 board) installed in your PC, you can connect your PC’s COM
port to TCC-100/100I’s RS-232 port, and then connect TCC-100/100I’s
RS-422/485 terminal block to one of the RS-422/485 serial board’s ports.
Alternatively, if you have already set up an RS-422 or RS-485 network, you can
also connect TCC-100/100I’s RS-422/485 terminal block directly to that network.
Next, start HyperTerminal or Moxa Terminal Emulator, and then open a
connection to both the COM port, and the port associated with TCC-100/100I’s
RS-422/485 port. Simply type a few characters on your PC’s keyboard. The
characters you type should show up in the HyperTerminal window that is
currently inactive, indicating that the typed characters were transmitted between
TCC-100/100I’s RS-232 port and RS-422/485 terminal block connector.
2-6

Installation
2-7
Termination Resistor Diagram
Termination is designed to
mitigate noise from the
RS-422/485 transmission
signals. If the network cable is
too long, undesirable
transmission-line effects will
arise. The best method for
mitigating energy on an unused
conductor is to dissipate the
RxD+
RxD-
Termination Resistor:
S3 On to Enable
S3 Off to Disable
R
energy as heat by terminating both ends of the unused conductor to ground with
resistors (so-called bi-directional termination). The resistance of the resistors
should be equal to the characteristic impedance of the line. The most common
RS-485 twisted pair has a characteristic impendence of 100-120 Ohm. Moxa's
termination technique is bi-directional termination, which offers excellent signal
integrity. With this technique, the line drivers can be located anywhere on the
network.
Function Diagram
TxD
RxD
RTS
CTS
GND
TxD+
TxD-
RxD+ (Data +)
RxD-(Data -)
RS-232
Line Driver
Isolation
RS-422/485
Line Driver
Communication
Controller
ADDC
Logic
RS-485
RS-422

Moxa TCC-100/100I User’s Guide
Isolation Block Diagram
Local Power
Data
Input
Data
Output
Optical
Isolator
Regulated
Power Supply
+5V
+5V
V+
+V
-
+5V +5V
12-30 VDC
Typical Applications
RS-485 Application
A typical RS-485 application for TCC-100/100I is depicted in the following
figure. In this scenario, two TCC-100I units are used to connect two PCs to an
RS-485 network. The third TCC-100I is used to connect the PLC—which is
designed for the RS-232 interface—to the RS-485 network. In this way, both PCs
are able to interact with the PLC and the LCD Display.
MOXA
TCC-100I
MOXA
TCC-100I
MOXA
TCC-100I
R
R
R
T
T
T
RS-485
Network
PC
PC
PLC
LCD Display
RS-232
RS-232
RS-232
PWR RS-232Tx RS-232Rx
Transio
RS-232toRS-422/485
converter
RS-232
RS-422/485
Tx+(B)
Tx (A)
Rx+(B)(Data+)
Rx (A)(Data )
RTS+(B)
RTS (A)
CTS+(B)
CTS (A)
SGND
V+
V
DC9~30V
TCC-100
PWR RS-232Tx RS-232Rx
Transio
RS-232toRS-422/485
converter
RS-232
RS-422/485
Tx+(B)
Tx (A)
Rx+(B)(Data+)
Rx (A)(Data )
RTS+(B)
RTS (A)
CTS+(B)
CTS (A)
SGND
V+
V
DC9~30V
TCC-100
PWR RS-232Tx RS-232Rx
Transio
RS-232toRS-422/485
converter
RS-232
RS-422/485
Tx+(B)
Tx (A)
Rx+(B)(Data+)
Rx (A)(Data )
RTS+(B)
RTS (A)
CTS+(B)
CTS (A)
SGND
V+
V
DC9~30V
TCC-100
2-8

Installation
2-9
RS-422 Application
A typical RS-422 application for TCC-100/100I is depicted in the following
figure. In this scenario, two TCC-100I units are used to create a point-to-point
connection between a PC and Scales. The advantage of using two TCC-100I units
to convert from RS-232, to RS-422, and then back to RS-232, is that the RS-422
cable connecting the two converters can be up to 1.2 km in length (this is quite an
improvement compared to the 15-m distance limitation imposed by the RS-232
interface).
MOXA
TCC-100I
MOXA
TCC-100I
RS-232
Rx(+/-) Tx(+/-)
w/ optional RTS/CTS
RS-422 Point-to-Point
Communication
PC Scales
PWR RS-232Tx RS-232Rx
Transio
RS-232to RS-422/485
converter
RS-232
RS-422/485
Tx+(B)
Tx (A)
Rx+(B)(Data+)
Rx (A)(Data )
RTS+(B)
RTS (A)
CTS+(B)
CTS (A)
SGND
V+
V
DC9~30V
TCC-100
PWR RS-232Tx RS-232Rx
Transio
RS-232to RS-422/485
converter
RS-232
RS-422/485
Tx+(B)
Tx (A)
Rx+(B)(Data+)
Rx (A)(Data )
RTS+(B)
RTS (A)
CTS+(B)
CTS (A)
SGND
V+
V
DC9~30V
TCC-100