MSA ProtoCessor FPC-ED2 User manual

Operating Manual
ProtoCessor Design Guide
FPC-ED2, FPC-ED4, FPC-E03, FPC-AD2
Revision: 10.F
Document No.:T18601
Print Spec: 10000005389 (F)
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Contents
1 About the ProtoCessor 5
1.1 Certification 5
1.2 ProtoCessor Family of Modules 6
1.2.1 ProtoCessor (FPC-ED2) 6
1.2.2 ProtoCessor (FPC-ED4) 6
1.2.3 ProtoCessor (FPC-E03) 6
1.2.4 ProtoCessor (FPC-AD2) 6
2 Implement the ProtoCessor from a Hardware Perspective 7
2.1 How to Implement the ProtoCessor Socket on OEM Hardware 7
3 ProtoCessor Socket PCB Footprint – Layout 8
3.1 Pin Assignment 8
3.1.1 ProtoCessor TTL Socket for 2x10 Header Pins 8
3.1.2 ProtoCessor Pin Voltage Levels 9
3.1.3 ProtoCessor Pin Headers 9
3.2 Location of Pins on the ProtoCessor 10
3.2.1 FPC-AD2 10
3.2.2 FPC-ED2 10
3.2.3 FPC-E03 10
3.2.4 FPC-ED4 10
3.3 Standoff Dimensions 11
4 ProtoCessor Power Requirements 12
5 Implement the ProtoCessor from a Software Perspective 13
5.1 ProtoCessor Supported Host & Field Protocol Communications 13
5.2 ProtoCessor Device/Field Supported Protocols 14
6 How ProtoCessor Works 15
6.1 Introduction 15
6.1.1 Full Function ProtoCessor 15
6.2 Configuration File 16
6.2.1 Application Specific ProtoCessor (ASP) 17
6.2.2 How to Implement and Test Any ASP ProtoCessor 18
7 ProtoCessor Simple Protocol (PSP) Specification 19
7.1 Purpose of the Protocol 19
7.2 Protocol Description 19
7.2.1 Quick Start – Demonstrates the Simplicity of the Application 19
7.2.2 Serial Parameters 19
7.2.3 Message Structure 20
7.2.4 Binary Packed Messages 20
7.2.5 Payload Contents 20
7.2.6 Writing to Output Data Objects 22
7.3 Error Conditions 22
7.3.1 Format of the Error Response 22
7.3.2 Error Response Table 22
3 ProtoCessor Design Guide

7.4 Using Change of Value Reads 23
8 Recommended Connectors, Cables and Mechanics 24
8.1 ProtoCessor Pin Headers 24
8.2 Expansion Connector for ASP – FPC-AD4 and FPC-AD5 24
8.3 Expansion Cable for ASP – FPC-AD4 and FPC-AD5 24
8.4 Mechanics – Standoff 24
9 Additional Information 25
9.1 Enclosure – Mechanical Design 25
9.2 Mechanical Drawings – ProtoCessor 26
9.2.1 Mechanical Dimension Drawing FPC-E03 26
9.2.2 Mechanical Dimension Drawing FPC-ED2 26
9.2.3 Mechanical Dimension Drawing FPC-ED4 27
9.2.4 Mechanical Dimension Drawing FPC-AD2 27
9.3 Specifications 28
9.4 Warnings 28
10 Limited 2 Year Warranty 29
ProtoCessor Design Guide 4

1 About the ProtoCessor
ProtoCessor is a family of embedded or external low cost, high performance Building and Industrial Automation multi-
protocol gateways.
With one part number, the ProtoCessor products are pre-programmed to automatically support one to many of the same or
different OEM products to multiple different protocols.
This guide provides an overview to the ProtoCessor family of protocol gateway solutions and the steps required to utilize
each gateway option.
By adopting the ProtoCessor solution 140+ Industrial and Building Automation protocols are instantly available. The
ProtoCessor solution translates from a common Serial or Ethernet protocol on the OEM’s controller to the desired field
protocol (Serial, Ethernet or LonWorks).
The ProtoCessor is cloud ready and connects with MSA Grid. For FieldServer Manager instructions, refer to the MSA Grid -
FieldServer Manager Start-up Guide on the MSA Safety website.
1.1 Certification
BTL Mark – BACnet Testing Laboratory
The BTL Mark on the FieldServer is a symbol that indicates that a product has passed a series of
rigorous tests conducted by an independent laboratory which verifies that the product correctly
implements the BACnet features claimed in the listing. The mark is a symbol of a high-quality BACnet
product.
Go to www.BACnetInternational.net for more information about the BACnet Testing Laboratory. Click
here for the BACnet PIC Statement. BACnet is a registered trademark of ASHRAE.
LonMark Certification
LonMark International is the recognized authority for certification, education, and promotion of
interoperability standards for the benefit of manufacturers, integrators and end users. LonMark
International has developed extensive product certification standards and tests to provide the
integrator and user with confidence that products from multiple manufacturers utilizing LonMark
devices work together. MSA Safety has more LonMark Certified gateways than any other gateway
manufacturer, including the QuickServer, ProtoCessor, ProtoCarrier and ProtoNode for OEM
applications and the full featured, configurable gateways.
5 ProtoCessor Design Guide

1.2 ProtoCessor Family of Modules
Full Function ProtoCessor and Application Specific ProtoCessor (ASP): These modules are designed on the OEM’s
controller by implementing a ProtoCessor serial TTL socket (3.3VDC to 5VDC). See voltage ranges in Section 3.1.2
ProtoCessor Pin Voltage Levels.
Ordering
Name
Interface Connections Certifications
Serial TTL RS-485 RS-422 Ethernet LonWorks BACnet BTL LonMark
FPC-ED2 1 1 1 Yes
FPC-ED4 1 1 1 Yes Yes
FPC-E03 1 1 Yes
FPC-AD2 1 1
1.2.1 ProtoCessor (FPC-ED2)
1.2.2 ProtoCessor (FPC-ED4)
1.2.3 ProtoCessor (FPC-E03)
1.2.4 ProtoCessor (FPC-AD2)
ProtoCessor Design Guide 6

2 Implement the ProtoCessor from a Hardware Perspective
2.1 How to Implement the ProtoCessor Socket on OEM Hardware
The OEM needs to implement a ProtoCessor socket on the board consisting of u-shaped 2 x 10 and 1 x 8 pin headers
(reserved pins) which include the TX/RX signals power supply.
• This socket will accommodate any current and future ProtoCessor.
• The socket is populated only when the need for the protocol exists.
7 ProtoCessor Design Guide

3 ProtoCessor Socket PCB Footprint – Layout
3.1 Pin Assignment
3.1.1 ProtoCessor TTL Socket for 2x10 Header Pins
PIN # Function Direction DTE Label Comments
1 Frame Ground (FG) Not DC Ground (0V)
2 VIN 3.3V-5.0V ±10%
3 TX From ProtoCessor TxD (out)
4 RX To ProtoCessor RxD (in)
5 CTS To ProtoCessor CTS (in)
6 RTS From ProtoCessor RTS (out)
7 DIO1 DSR (in) Alternative I/O: SPI-SCK
8 DIO2 DTR (out) Alternative I/O: SPI-CS
9 DIO3 DCD (in)
10 Reserved
11 0V Circuit Ground
12 SCL I2C Clock line – Open Drain,
10k Pull-up to VIN
13 SDA I2C Data Line – Open Drain,
10k Pull-up to VIN
14 DIO4 RI (in) Alternative I/O: SPI-MISO
15 DIO6
16 DIO7
ProtoCessor Design Guide 8

PIN # Function Direction DTE Label Comments
17 DIO5 Alternative I/O: SDI-MOSI
18 DIO8
19 Reserved
20 Reserved
21 RS-485 + (ISO) I/O Pass through Connection from Terminal Block
22 RS-485 - (ISO) I/O Pass through Connection from Terminal Block
23 RS-485 GND (ISO) GND Pass through Connection from Terminal Block
24 RS-232 TX OUT Reserved (Not used)
25 RS-232 TX INT Reserved (Not used)
26 RS-232 TX IN Reserved (Not used)
27 RS-232 TX OUT Reserved (Not used)
28 Spare I/O Reserved (Not used)
Serial Peripheral Interface (SPI) is supported with signals: SCK, CS, MISO and MOSI
3.1.2 ProtoCessor Pin Voltage Levels
Description Pin # Min Max Unit
Input High Voltage 4, 5 2 5.5 V
Input Low Voltage 4, 5 0 0.8 V
Input High Voltage All other inputs 2 3.6 V
Input Low Voltage All other inputs 0 0.8 V
Output High Voltage All Outputs except pins 12, 13 2.4 3.6 V
Output Low Voltage All Outputs except pins 12, 13 0 0.8 V
3.1.3 ProtoCessor Pin Headers
ProtoCessor recommends use of the following SAMTEC Pin Headers on host board:
Part Numbers TLW-1xx-x-S or MTLW-1xx-x-S
Manufacturer SAMTEC
Link to Data Sheets www.samtec.com/ftppub/pdf/tsw_th.pdf
9 ProtoCessor Design Guide

3.2 Location of Pins on the ProtoCessor
3.2.1 FPC-AD2
3.2.2 FPC-ED2
3.2.3 FPC-E03
3.2.4 FPC-ED4
ProtoCessor Design Guide 10

3.3 Standoff Dimensions
NOTE:Material nylon 6/6 (RMS-01). Flame retardant, nylon (RMS-19). Color – natural.
See Section 8.4 Mechanics – Standoff for additional information.
11 ProtoCessor Design Guide

4 ProtoCessor Power Requirements
NOTE:Visit the MSA website ProtoCessor page for the latest information.
Power Requirement for ProtoCessor ASP at 3.3V through 5 VDC
Standalone ProtoCessor
ProtoCessor Type Mk 2 3.3VDC 5 VDC
FPC-AD2 (Typical) 100mA 120mA
FPC-AD2 (Maximum) 120mA 140mA
NOTE: These values are ‘nominal’ and a safety margin should be added to the power supply of the host system.
A safety margin of 25% is recommended.
Power Requirement for ProtoCessor FFP-Modules
Standalone ProtoCessor
ProtoCessor Type Mk 3 3.3VDC 5VDC
FPC-ED2 (Typical) 425mA 280mA
FPC-ED2 (Maximum) 530mA 350mA
FPC-ED4 (Typical) 582mA 355mA
FPC-ED4 (Maximum) 725mA 480mA
NOTE: These values are ‘nominal’ and a safety margin should be added to the power supply of the host system.
A safety margin of 25% is recommended.
ProtoCessor Design Guide 12

5 Implement the ProtoCessor from a Software Perspective
OEMs need to select a common host side protocol that the ProtoCessor can understand. ProtoCessor supports a wide
range of legacy host protocols (like Modbus), but for OEM devices that do not have host protocol, 2 alternatives are
available:
• Implement our PSP ASCII protocol. (ProtoCessor Simple Protocol). It takes about 1 day to implement. Refer to
Section 7 ProtoCessor Simple Protocol (PSP) Specification for the protocol spec.
• If the OEM has a proprietary host protocol, FieldServer can write the driver on the ProtoCessor Host/Socket platform
for an NRE fee.
5.1 ProtoCessor Supported Host & Field Protocol Communications
The following table lists the currently supported OEM’s Host/Socket and Field Protocols. The list of supported protocols is
constantly increasing and it is advisable to contact ProtoCessor or refer to the website for a more updated list.
NOTE:Visit the MSA Safety website for the complete list of supported protocols.
OEM’s Host Serial or Ethernet
Protocols
Serial Field
Protocols
Ethernet Field
Protocols
FieldBus
Protocols
Modbus RTU BACnet MS/TP Modbus TCP/IP LonWorks
Modbus ASCII BACnet PTP Allen Bradley DF1
ProtoCessor PSP Driver Modbus RTU DNP 3.0
BACnet MS/TP Modbus ASCII BACnet/IP
Metasys N2 Open BACnet MS/TP BACnet Ethernet
XML over HTTP Metasys N2 Open EtherNet/IP
Allen Bradley DF1 Allen Bradley DF1 Allen Bradley CSP
Modbus TCP/IP DNP 3.0 Serial DNP 3.0 Ethernet
BACnet/IP J-Bus GE-SRTP
LonWorks GE-EGD
EtherNet/IP Omron FINS
Allen Bradley CSP SNMP Ver 1 & 2C
DNP 3.0 Serial or Ethernet XML over HTTP
GE-SRTP JSON
GE-EGD
SNMP Ver 1 & 2C
OEM’s Custom Serial Driver
JSON
13 ProtoCessor Design Guide

5.2 ProtoCessor Device/Field Supported Protocols
ProtoCessor Design Guide 14

6 How ProtoCessor Works
6.1 Introduction
From a software standpoint, all three families of ProtoCessor work in the same fashion. ProtoCessor functions as an
embedded gateway, enabling the OEM’s equipment to rapidly utilize different protocols to interface with various Building
and Industrial Automation networks. The ProtoCessor solves communication and protocol conversion problems, while
enabling the OEM’s to focus on their core expertise. The ProtoCessor’s extensive driver library provides a wide range of
interoperability solutions. The way our devices work is as follows:
• We take a CSV file and we map the memory registers of the OEM’s device to the various field protocols properties.
• The CSV file gets downloaded to the ProtoCessor over Ethernet and the memory registers are stored/managed in a
data array inside the ProtoCessor.
• The ProtoCessor can be a master or a slave depending on what the OEM device is (master or a slave).
• We poll the OEM’s device and continually update the registers in the data array. When the front end (BMS) polls us on
the field protocol side, we will server up to the front the most recent data that is stored in the data array.
• This implementation allows the OEM the ability to instantly support any protocols that we support.
For the latest list of available drivers visit the MSA Safety website.
6.1.1 Full Function ProtoCessor
The ProtoCessor is user configurable, has more memory and supports multiple protocols. All modules have an Ethernet
port for remote diagnostics and configuration.
15 ProtoCessor Design Guide

6.2 Configuration File
The driver configuration file (CONFIG.CSV) is in comma-delimited format which can be edited using spreadsheet programs
or any text editor.
Every ProtoCessor has an Ethernet port. The port is used for remote configuration, diagnostics and Ethernet protocol
translation.
ProtoCessor point counts & certifications:
ProtoCessor Point Count
Level 1 Level 2 Level 3
FPC-ED2 1200 N/A N/A
FPC-E03 1500 5000 10000
FPC-ED4 1000 2500 4096
The CONFIG.CSV file is loaded into these devices through the Ethernet port. It can be retrieved using the FieldServer
FS-GUI (Graphic User interface) via Ethernet. Refer to the MSA Safety webpage for more information. Contact FieldServer
technical services for assistance in mapping the configuration file to a particular application.
FS-GUI’s most significant features:
• Set IP Address for field protocol.
• Generate XIF files for LonWorks network.
• Transfer files (CSV configuration, firmware, etc.) to and from the ProtoCessor.
• Monitor the ProtoCessor’s internal data and parameters, including Socket communications. These are the
communications between ProtoCessor and the Host CPU. It displays the TX and RX packet communications, as well
as the total number of bad packets.
• Change or update ProtoCessor internal data parameters.
• Delete files on a ProtoCessor.
• Restart the ProtoCessor.
• Create serial and Ethernet data captures for diagnostics.
• View error messages.
ProtoCessor Design Guide 16

6.2.1 Application Specific ProtoCessor (ASP)
The ASP ProtoCessor has been designed specifically for OEMs with high-volume/cost sensitive products requiring efficient
but affordable protocol support. The ASP has been designed for “Plug and Play” installation – no software is required. This
is to ensure ease of installation and support by the OEM and their customers.
The ASP supports up to 100-150 points mapped to the desired field protocol. The ProtoCessor is programmed at the factory
with a static mapping configuration which cannot be changed in the field. Several different static mappings are supported via
the DIP switch user defined functions. The two banks of DIP switches enable the users to quickly configure the serial
protocol settings without the need for any 3rd party software.
Settings available via the DIP switches include:
• BACnet MS/TP MAC Address
• Baud rate (including auto-baud setting for BACnet MS/TP)
• Node-ID
Four special user defined functions can be selected via the DIP switches. These functions could be protocol or device
related. For example, the same ASP ProtoCessor can be used on four different chiller models. The DIP switches can be
used to select the specific profile used on a specific model of chiller.
ASP’s have an optional 20-pin Expansion I/O Interface that includes:
• Twelve GPIO pins that can support any combination of 12 Digital I/O or Analog Inputs.
• Eight power pins (4 ground and four 3.3V pins) that can be used to power an external device up to 500 mA at 3.3V
(LED’s).
• To access the 20 pins, the 20 socket can be laid directly on OEM hardware or can be connected with the use of a
ribbon cable (needs to be purchased separately). Refer to Section 8 Recommended Connectors, Cables and
Mechanics for connectors and cables.
17 ProtoCessor Design Guide

6.2.2 How to Implement and Test Any ASP ProtoCessor
• The OEM provides the Modbus register list for the product that the ASP-485 will be designed into.
• MSA Safety programs, configures and tests the gateway with the Modbus register list that was provided to support
BACnet MS/TP. The ASP is not field programmable so the OEM must do the testing for configuration on the
ProtoCessor FPC-ED2. Most customers will want a proof concept before designing the ProtoCessor socket onto their
hardware. The ProtoCessor allows OEMs to quickly create a proof of concept to provide their management team.
• MSA Safety ships a pre-programmed sample of a ProtoCessor FPC-ED2 with all the configurations for the OEM’s
product lines.
• MSA Safety schedules a 60-minute walkthrough for setup and validation.
• The OEM connects their device to the ProtoCessor via RS-232 or RS-485. The OEM can also wire TTL signals that
come off their micro controller and connect them to the ProtoCessor TTL socket. All of this can be done without
designing a ProtoCessor socket.
• MSA Safety provides a BACnet Explorer that allows the OEM to fully test their product on BACnet MS/TP from their
office.
• Once the proof of concept is completed, the customer sends MSA Safety the csv file from the ProtoCessor:
◦ No more changes to the config
◦ Customer starts ProtoCessor socket board spin
◦ Customer needs to purchase the PIC development tools
◦ MSA Safety sends the customer the preprogrammed ASP
• MSA Safety creates an ASP part number in Quick Base.
• MSA Safety gets a blanket order.
• The OEM’s board comes back with the ProtoCessor socket on it.
• To validate the new hardware, the OEM can take the FPC-ED2 module off the ProtoCessor and put it on their new
hardware to validate that the hardware is complete/functioning.
• The OEM then puts the ASP-485 on the hardware and validates it with the BACnet Explorer to test that everything is
working.
• The ASP-485 programming may need some scaling correction. When changes are needed:
◦ The OEM must inform MSA Safety what alterations are required for each point
◦ MSA Safety’s engineers will reprogram the ASP with the changes requested
◦ MSA Safety sends the OEM a binary image to reprogram the ASP using the PIC tools
◦ This process continues until no more changes are needed
• MSA Safety freezes the code.
• MSA Safety ships the first production order.
• MSA Safety provides an installation manual, showing how to install the product on BACnet.
• MSA Safety provides customized webinar training for the OEM’s support team such as how to install and diagnose
problems in the field.
ProtoCessor Design Guide 18

7 ProtoCessor Simple Protocol (PSP) Specification
7.1 Purpose of the Protocol
The ProtoCessor Simple Protocol (PSP) is recommended in instances where the ProtoCessor is the Server and the OEM
CPU is the Client.
• Implemented on the “Host” or “Application” CPU on the OEM circuit board (Microcontroller).
• Defined as an ASCII protocol in order to facilitate debugging, analysis and implementation.
• Allows data to be transferred to and from the ProtoCessor.
• Allows the Host Microcontroller to configure aspects of the ProtoCessor such as BACnet MS/TP MAC Address, Node-
ID, baud rate.
• Data that is written to the ProtoCessor is available to other devices on the ProtoCessor Ethernet connection. Data
written to the ProtoCessor by other devices over the Ethernet protocol is available to be read by the Host CPU.
7.2 Protocol Description
7.2.1 Quick Start – Demonstrates the Simplicity of the Application
Assuming a ProtoCessor is installed with a Factory Default configuration where there are no configuration commands
necessary; there is no need to configure any aspects of the ProtoCessor unless the application justifies the additional
complexity.
• The first data point from the ProtoCessor is the “Read Data”. The transaction between the Application Microcontroller
and the ProtoCessor would appear as follows:
From Host CPU/MCU:RD-NA:data,OF:0<cr>
Response from ProtoCessor:27.3<cr>
• The 27th value in the ProtoCessor is the “Write Data”. The transaction would appear as follows:
From Host CPU/MCU:WD-NA:data,OF:26,VA:23.9<cr>
Response from ProtoCessor:OK<cr>
• The FMT command in the poll from the Host CPU to the ProtoCessor can be used to specify the format of the data
traveling to and from the ProtoCessor. If no FMT is specified, then the ProtoCessor returns a floating point value.
From Host CPU/MCU:RD-NA:data,OF:0,FMT:H<cr>
Response from ProtoCessor:0x89CA<cr>
7.2.2 Serial Parameters
The PSP has the following default serial parameter settings:
Baud 38400
Data Bits 8
Parity N
Stop Bits 1
Minimum Poll Delay 10ms
Recommended Poll Delay 100ms
19 ProtoCessor Design Guide

7.2.3 Message Structure
Every PSP Protocol Packet has the same basic structure:
Start Payload Terminator
: {see Section 7.2.5 Payload Contents) <CR>
7.2.4 Binary Packed Messages
Binary Packed messages were considered but the implementation of these was rejected for the following reasons.
• Byte Order
• Floating Point Format
• Floating Point Order
As an alternative to this it will be possible to use block reads for faster data transfer. Another option is to use the RCOV
functionality implemented in this protocol.
7.2.5 Payload Contents
Payload Packets can generally be defined as:Command – parameter 1, parameter 2 <CR>
Three basic types of commands exist:Transferring Data, Setting Parameters and Issuing Control Commands.
Transferring Data Commands
Required Parameter Optional Parameter
Description Command Parameter 1 Parameter 2 Parameter
3Parameter 4
Read Data from a Data Array in the
ProtoCessor RD Data Array Name
Data Array
Offset -FMT (default to decimal unsigned integer)
Write data to a Data Array in the
ProtoCessor WD Data Array Name
Data Array
Offset value FMT (default to decimal unsigned integer)
Block Read (Future) RB Data Array
Name
Data Array
Offset
Data
Length
Change Of Value Read RCOV - - -
Change of Value Read and Ack RCOVA - - -
Simple COV ACK A or ACK - - -
ProtoCessor Design Guide 20