OPTO 22 G4LC32 User manual

G4LC32 USER’S GUIDE
Form 340-050824 — August, 2005
43044 Business Park Drive, Temecula, CA 92590-3614
Phone: 800-321-OPTO (6786) or 951-695-3000
Fax: 800-832-OPTO (6786) or 951-695-2712
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G4LC32 User’s Guideii
G4LC32 User’s Guide
Form 340-050824 — August, 2005
All rights reserved.
Printed in the United States of America.
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no responsibility for possible inaccuracies or omissions. Specifications are subject to change without notice.
Opto 22 warrants all of its products to be free from defects in material or workmanship for 30 months from the
manufacturing date code. This warranty is limited to the original cost of the unit only and does not cover
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G4LC32 User’s Guide
TABLE OF CONTENTS
Welcome ................................................................................................... v
About This Manual ......................................................................................................................... v
Document Conventions ................................................................................................................ v
G4LC32 Revised Features ..................................................................... 1-1
Introduction .......................................................................................... 2-1
The G4LC32 Model 200 Processor ......................................................................................... 2-1
Basic Architecture ............................................................................................................... 2-3
G4LC32 Features .................................................................................................................. 2-5
Configuration ....................................................................................... 3-1
Front Panel Hardware and Indicators ................................................................................... 3-1
Processor Status LEDs ......................................................................................................... 3-1
LCD Display ........................................................................................................................... 3-2
Messages ................................................................................................................................ 3-3
Keyboard ............................................................................................................................... 3-3
Communication Status LEDs ............................................................................................ 3-4
Front Panel Setup ....................................................................................................................... 3-4
View Mode ............................................................................................................................ 3-5
Change Mode ....................................................................................................................... 3-6
Communication Switches ....................................................................................................... 3-11
RS-422/485 Switch Settings .......................................................................................... 3-11
RS-232 Switch Settings ................................................................................................... 3-11
IRQ Switch Settings .......................................................................................................... 3-11
Installation ............................................................................................ 4-1
Dimensions .................................................................................................................................... 4-1
Mounting ...................................................................................................................................... 4-2
Power Connections ..................................................................................................................... 4-3
RAM and Flash EPROM Installation ...................................................................................... 4-4
Display EPROM Installation ..................................................................................................... 4-7
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G4LC32 User’s Guide
TABLE OF CONTENTS
Communications and Cables ................................................................ 5-1
Serial Communications ............................................................................................................. 5-1
Overview ................................................................................................................................ 5-1
Cables and Connectors ...................................................................................................... 5-1
Connectors ............................................................................................................................ 5-3
Wiring ..................................................................................................................................... 5-3
Fusing for RS-232 +5V ..................................................................................................... 5-5
Connections to a Host PC ................................................................................................. 5-6
Local Communications .............................................................................................................. 5-9
Overview ................................................................................................................................ 5-9
Cables and Connectors ...................................................................................................... 5-9
Wiring .................................................................................................................................. 5-10
ARCNET ................................................................................................................................ 5-10
Cables and Connectors .................................................................................................... 5-11
Software and Firmware ....................................................................... 6-1
Software ......................................................................................................................................... 6-1
Firmware Updates ....................................................................................................................... 6-1
RAM and Flash EPROMs ............................................................................................................ 6-1
Running from Flash EPROM and Making Changes .......................................................... 6-1
G4LC32 Hardware Specifications ........................................................ 7-1
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G4LC32 User’s Guide
WELCOME
ABOUT THIS MANUAL
Thismanualisorganizedasfollows:
•Chapter 1: G4LC32 Revised Features
•Chapter 2: Introduction
•Chapter 3: Configuration
•Chapter 4: Installation
•Chapter 5: Communications and Cables
•Chapter 6: Software and Firmware
•Chapter 7: G4LC32 Hardware Specifications
DOCUMENT CONVENTIONS
•Bold typefaceindicates text to be typed. Unless otherwise noted, suchtextmay be entered in upper or
lower case. (Example: “At the DOS prompt, type cd \windows.”)
•
Italic typeface indicates emphasis andis used for booktitles.
(Example: “See the
OptoControl User’s Guide for details.”)
• Filenames appear in all capital letters. (Example:“Open the file TEST1.TXT.”)
• Keynames appear in small capitalletters.(Example: “Press SHIFT.”)
• Keypress combinations are indicated byplus signs between two ormore key names. For example,SHIFT+F1
isthe result of holding down the SHIFT key, then pressing and releasingtheF1 key. Similarly, CTRL+ALT+DELETE is
theresult of pressing and holding the CTRL and ALT keys, then pressing and releasingthe DELETE key.
• “Press”(or “click”) means pressand release when used inreference to a mousebutton.
• Menucommands are sometimes referred towith the MenuÆCommandconvention. For example,
“Select FileÆRun” means toselect the Run command fromtheFile menu.
• Numberedlists indicate procedures tobefollowed sequentially.Bulleted lists (such as thisone) provide
generalinformation.
v

G4LC32 User’s Guide
WELCOME
vi

G4LC32 User’s Guide
G4LC32 REVISED FEATURES
G4LC32controllers manufactured afterJanuary 1994 have beenmodified and can becompatible with theoriginal
G4LC32controllers. The followingtable describes the changes.
Important: Connectorswired for other Mistic200controllers may not becompatiblewith the G4LC32. Usethe
connectorsprovidedandrefertotheconfiguration label for wiring information.
1-1
Feature New G4LC32 Original G4LC32
EPROMs
Flash EPROMs.
Firmware update is downloaded
to the EPROMs by using the
FLASH utility
UV EPROMs.
Firmware update requires
physical removal and installation
of UV EPROMs.
RAM Expansion
Requires additional RAM chips.
See "RAM and Flash EPROM
Installation, Flash EPROM
Jumpers" for chip part numbers.
Requires expansion kits
G4LC32RAMEX.5M
G4LC32RAMEX2M
G4LC32RAMEX4M
RS-232 Ports
Ports are green 7-pin
mini-receptacles. Cables use
green 7-pin mini-plug,
Phoenix Contact
P/N MCVR 1,5/7-ST-3,81
Use subminiature 9-pin D
connectors.
115.2 K maximum baud rate 38.4 K maximum baud rate
+ 5 VDC available from Pin 1 on
COM0 and COM1 + 5 VDC source not available
RS-485 Ports
Ports are green 7-pin
mini-receptacles. Cables use
green 7-pin mini-plugs,
Phoenix Contact
P/N MCVR 1,5/7-ST-3,81
Ports are green 7-pin
receptacles. Cables use
larger green 7-pin plugs,
Phoenix Contact
P/N MVSTBW 2,5/7-ST-5,08.
Switches used to terminate and
bias ports.
Jumpers used to terminate and
bias ports.
ARCNET Ports Straight connection to port. Requires right angle elbow
to port.
Power Connector
Straight connection; can be
connected without opening
controller's front panel door.
Connection is at a right angle;
must open controller's front
panel door to access.
Power Requirements + 5 VDC (± 0.1) @ 2 A + 5 VDC (± 0.1) @ 2.5 A
- 5 VDC (± 0.25) @ 20 mA
Number of Circuit Boards 3 7
Weight 4.3 lbs 5.5 lbs
CHAPTER 1

G4LC32 User’s Guide
G4LC32 REVISED FEATURES
1-2

G4LC32 User’s Guide
INTRODUCTION
THE G4LC32 MODEL 200 PROCESSOR
TheG4LC32 Model 200 Processor is a localprocessing unit designed to be used ina Mistic Model200 System. A
Mistic system is the combination of a powerful industrial microcomputer, highly intelligent I/O, an amazing new
control language, and a better idea for industrial packaging. This combination is designed with one thought in
mind— to allow youto quickly and easily implementyour industrial control applications.
G4LC32 Model 200 Processor
How A User Application Works
Usethe G4LC32 Model200 Processor torun the applicationprograms that youdevelopedon a PCworkstation and
downloadedtotheG4LC32Model200Processor.Afteryourapplicationhas beendownloaded tothe targetG4LC32
Model200 Processor and debugged usingthe Cyrano 200 Debugger,the PC workstation is nolonger needed. The
G4LC32Model 200Processor runs yourapplication stand-alone.For very largedistributed controlapplications,you
canuse more than one G4LC32 Model 200 Processor networked together via the ARCNET portorvia a multidrop
RS-485 communications port. The G4LC32 application program can easily interface to supervisory and operator
connectdevices. Refer to FactoryFloor/OptoControl formore information.
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CHAPTER 2

G4LC32 User’s Guide
I/O Units (Bricks)
TheG4LC32Model 200Processornot onlyhandles allthelogic torunyourapplicationprograms butitcommunicates
withI/O units(Bricks) as well.The G4LC32 Model200 Processorconnects to I/Ounits in twodifferent ways:(1) you
canuse localI/O unitswhich communicatewith theG4LC32 overa1.4 MHzparallel bus(a 34-conductor,flat-ribbon
cable),or (2) youcan use remoteI/O units whichcommunicate with theG4LC32 over atwo-wire RS-422/485 serial
communicationlink operating at up to115.2 KBd.
Theadvantage of local I/O is speed (1.4 MHz, ~1.5Mbps).The disadvantage is that the total bus length islimited
to200 feet. As many as 139 local I/O units canbeconnected to one G4LC32. You scan mix and match both digital
andanalog I/O units, asneeded by your application.Each I/O unit can haveup to 16 I/Opoints (modules), thus one
G4LC32 can control up to 2,224 I/O points on the local bus. CRC 16-error detection is included in every message
transactionto insure safe, reliable operation. Iflonger distances and/or more I/O pointsare required, then panels
containingremote I/O units may be added to thesystem.
The advantage of remote I/O is that you can distribute your I/O units over large distances. The G4LC32 and the
remote I/O units can be separated by distances up to 3,000 feet (even longer distances with repeaters). The
disadvantageis a slower baud rate of 115KBd. You canuse a single twisted pair of wireto provide cost-effective
communicationsover an RS-422/485communications link. AMistic controller supportsthreeremote I/O linksand
onehost communicationlink,or fourremote I/O linkswhen ARCNET isused for hostcommunications. Four remote
I/O links can be used in stand-alone applications. As many as 100 (256 with repeaters) remote I/O units can be
connectedto each remoteI/Olink. CRC 16-errordetectionis included inevery message transaction toinsure safe,
reliableoperation.
EachI/O unit contains a brain board with its own powerful 16-bit 80C196processor. The processor in the I/O unit
performsan incredibly usefulset of commoncontrol functions likehigh speed countingand PID controlat the brain
boardlevel. As a result, the unburdened G4LC32 Model200Processor can execute control logic with remarkable
speed.
Software
TheG4LC32 Model 200 Processor provides support for Cyrano 200 and OptoControl. It runsamultitasking kernel
whichcan runup to32 separatecharts (tasks) simultaneously. Acomplicatedcontrol applicationcan besegmented
byfunctions enabling each function to berepresented by its own unique chart.
Communications
The G4LC32 features four serial ports; two switch-selectable RS-422/485 or RS-232 ports and two
RS-422/485-onlyports. Baud rates from 300 to 115 K canbeselected by means of the front panel keypad.
Any of the four serial ports or ARCNET port can be used for communications to a remote PC workstation. The
RS-422/485portswouldtypicallybeused whenseveralserialdevicesmustbe connectedtooneserialcommunication
line.As many as 100devices can be connected toa RS-422/485 port ina multidrop application. Other typicaluses
for the RS-422/485 port are (1) for applications requiring a high degree of noise immunity, (2) the capability of
transmittingover longer line lengths (up to 3000 ft.)and(3) transmission at higher baud rates.
INTRODUCTION
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G4LC32 User’s Guide
Two of the serial ports, COM0 and COM1 can be used as RS-232 ports or as RS-422/485 ports. Plug removable
terminalblocks are provided for both the RS-422/485and the RS-232 connections. The RS-232 portscanbe used
byyour application program tocommunicate with standard serial devicessuch as printers, barcodereaders, etc.
AnARCNETport is provided for even faster communications between units. Opto 22 supports star type ARCNET
networks. You can connect as many as 254 G4LC32’s (or other ARCNET devices) to the ARCNET network. The
ARCNET network uses standard RG62A/U coaxial cable and it runs at 2.5 MHz.
Abattery backed real-time clock is providedfor time dependent tasks.
Front Panel
The G4LC32 features a front panel with a 4-line by 20-character, backlight LCD display, a 25-button keypad, LED
statusindicators for POWER, PROCESSOROK,FAULT andcommunicationsstatus LEDs. From thefrontpanel, you
canenter a setupmodewhich allows youto view and/or changethe G4LC32 address, thesecurity passwords and
theserial port baud rates.If you download theterminal task from Cyrano200 or OptoControl, thenyoucan use the
displayand keyboard as a terminal to view andor set parameters in your Cyrano 200 applicationsprogram. More
informationonthe G4LC32 front panel will be provided in a later section.
Basic Architecture
The G4LC32 processor’s 32-bit architecture, 512 KB of battery backed RAM (expandable to 4 MB) and 512 KB of
FlashEPROM (expandable to 1 MB) allows you to execute largecontrol applications with extensive data storage
requirements.
Theheart ofthe G4LC32Model 200Processor isa 32-bit68020 microprocessorcoupled witha68881 floating-point
mathcoprocessor. The 68881math coprocessor supportsIEEEfloating-point math foraccuratecalculations.
ARCNETsupport allows multiple Mistic controllers tobe organized into large, distributed systems.
INTRODUCTION
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G4LC32 User’s Guide
Ablock diagram of the G4LC32 is shown in the following figure.
G4LC32Block Diagram
INTRODUCTION
2-4

G4LC32 User’s Guide
G4LC32 Features
Featuresof the G4LC32 are:
• 32-bit68020 processor with68881 math coprocessor
• High-speed16.67 MHz clock
• Fourhigh-speed serial ports (115.2KBd)
2 RS-232 or RS-422/485 ports
2RS-422/485 only ports
• ARCNET port (2.5 Mbps)
• 4-lineby 20 character backlightLCD display
• 25-keymembrane keypad
• Support for remote and local I/O
• LEDindicators for processor,I/O, and communications diagnostics
• 512KBbattery backed RAM expandable to 4 MB
• 512 KB Flash EPROM expandable to 1 MB
• Battery-backedreal-time clock
• Multi-taskingruns up to31user tasks simultaneously
• IEEEfloating-point math
• SupportsCyrano 200 and OptoControl
• Controlsupto2224 points of local I/O
• Controls up to 4096 points of remote I/O on each serial port
INTRODUCTION
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G4LC32 User’s Guide
INTRODUCTION
2-6

G4LC32 User’s Guide
CONFIGURATION
FRONT PANEL HARDWARE AND INDICATORS
Thefollowing figure shows a diagram of the front panel of the G4LC32Model200 Processor.
G4LC32Front Panel
Processor Status LEDs
At the top of the G4LC32 front panel are three LED status indicators. Their function is as follows:
POWER The red POWER LED comes on whenever 5 VDC power to the G4LC32 is above
4.85VDC.
PROCESSOR OK Thegreen PROCESSOROK LEDindicator ison wheneverthe 68,020processoris outof
resetand is executingcode.
FAULT The red FAULT LED indicator turns on when the battery (P/N G4BATT32) is low.
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CHAPTER 3

G4LC32 User’s Guide
LCD Display
The G4LC32 front panel has a green, backlit 4-line by 20-character LCD display. The display and the keyboard
togethermake upa terminal fordata entry anddisplay.Each characteron the displayis a 5x 8 dotmatrix whichcan
displaythe complete ASCII character set.Upon power up, the followingmessageis displayed:
SYSTEM DIAGNOSTICS
Thenthe message:
DIAGNOSTICS COMPLETE
Ifeverything checks out correctly (butyou do not have ARCNET connected),then the display will showamessage
similarto the following:
DISPLAY REV:1.11
MisticKernel 1.39
No ARCNET activity
or if you are connected to ARCNET and the network is up and running, you will see:
DISPLAY REV:1.11
MisticKernel 1.39
systemready
Youcan ignorethe “NoARCNET activity”message ifyou donot haveARCNET connected.The abovemessages will
vary depending upon the revision level of the front panel display EPROM, and upon the revision level of the last
downloadedupgrade to the Flash EPROM.
DuringSETUP,thedisplay is used to prompt you to enter the setup parameters from the keyboard.
Ifyou are running Cyrano 200 or OptoControland you have downloaded the terminaltaskto the G4LC32, then the
displayis usedto showparameters fromyour application’s program,such as thevalue ofa variable,the statusof an
I/O point, etc. For more information on using the display in terminal mode, see the Cyrano 200 or OptoControl
manual.
CONFIGURATION
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G4LC32 User’s Guide
Messages
Uponpower up, the display will showamessage similar to the following:
DISPLAY REV:1.11
Mistic1Kernel 1.39
Message
wherethe actual
Message will be one of the following:
Keyboard
Unlessyou have downloaded theterminaltask or are usingauser-definedtaskthat uses the keyboard, thenmost
ofthe keys onthe front panelwill not beactive. In thiscase the keyboardis only usedto enter setupparameters for
theG4LC32. Seethesection onFrontPanel Setupforthe useofkeyboard anddisplay to enterand/or change setup
parameters.
Ifyou havedownloaded theterminal taskor auser-definedtask thatuses thekeyboard, thenvariouskeys’functions
will depend upon the downloaded task (chart). The keyboard is used to view and/or change parameters in your
applicationsprogramterminal task. You can,forexample, use the keyboard to turn I/O points ON or OFF.
Message Description
Low Battery When this message appears, you need to change the
battery in the G4LC32.
Bad Memory The RAM memory failed the power up diagnostic test.
Bad Math Chip The 68,881 math coprocessor failed the power up
diagnostic test.
COM0 Bad The COM0 port failed the power up diagnostic test in the
loopback mode.
COM1 Bad The COM1 port failed the power up diagnostic test in the
loopback mode.
COM2 Bad The COM2 port failed the power up diagnostic test in the
loopback mode.
COM3 Bad The COM3 port failed the power up diagnostic test in the
loopback mode.
Local Bus Bad The Local Bus failed the power up diagnostic test.
ARCNET problem The ARCNET port could not be initialized upon power up.
No ARCNET
activity
Displayed if the ARCNET port is not connected. If the
ARCNET port is connected to an active network, hen the
network is not responding. This could indicate that the
other ARCNET devices are not ON or the cable is broken.
System ready Displayed if the ARCNET port is connected to an active
ARCNET network.
CONFIGURATION
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G4LC32 User’s Guide
Communication Status LEDs
A group of red LEDs in the center of the front panel indicate status of the serial communication lines. Their
functionsare:
FRONT PANEL SETUP
You canuse the frontpanel display andkeyboard to performa setup forthe G4LC32. Setuplets you viewor change
thefollowing functions:
(1) Host port designation.
(2) Communication protocol.
(3) G4LC32 address.
(4) Baud rate for any of the four serial ports.
(5) Autobootoption.
(6) Kernelor Loader boot option.
(7) Run From RAM/Run From ROM option.
(8) Passwords forallthree security levels.
LED Description
RX0 This red LED is ON whenever the G4LC32 is receiving data on the COM0 port.
RX1 This red LED is ON whenever the G4LC32 is receiving data on the COM1 port.
RX2 This red LED is ON whenever the G4LC32 is receiving data on the COM2 port.
RX3 This red LED is ON whenever the G4LC32 is receiving data on the COM3 port.
TX0 This red LED is ON whenever the G4LC32 is transmitting data from the COM0 port.
TX1, This red LED is ON whenever the G4LC32 is transmitting data from the COM1 port.
TX2 This red LED is ON whenever the G4LC32 is transmitting data from the COM2 port.
TX3 This red LED is ON whenever the G4LC32 is transmitting data from the COM3 port.
IRQ0 This red LED is ON whenever the interrupt line for COM0 is active.
IRQ1 This red LED is ON whenever the interrupt line for COM1 is active.
IRQ2 This red LED is ON whenever the interrupt line for COM2 is active.
IRQ3 This red LED is ON whenever the interrupt line for COM3 is active.
LOCAL TX This red LED is ON whenever the G4LC32 is transmitting data onthe Local I/O Bus.
LOCAL RX This red LED is ON whenever the G4LC32 is receiving data on the Local I/O Bus.
ARCNET
ACTIVE This red LED is ON whenever there is communication on the ARCNET Bus and the G4LC32 is an active node.
CONFIGURATION
3-4

G4LC32 User’s Guide
To enter the SETUP MODE, press the SETUPkeyon the keyboard. Youwillget the following display:
SETUP MODE:
<ESC> TO EXIT
<REQ> TO VIEW
<ENTER> TO CHANGE
Ifyou do not wish to VIEW or CHANGE, thenpressthe ESC key on the keyboard. You will bereturnedto the initial
display, and theSETUPMODE will be terminated.For security reasons, theSETUP MODE has a time-outfunction.
Ifthere is nokeyboard activity forapproximately 3 minutes,then the SETUPMODE is alsoterminated. Pressing the
REQ key puts you in the VIEW MODE. Pressing the ENTER key puts you in the CHANGE MODE.
View Mode
Fromthis mode you can display all ofthe G4LC32 setup parameters. The first displaythatyou get when you enter
the VIEW MODE will be similar to the following:
VIEW MODE:
HOST PORT: COM1
PROTOCOL: BINARY
PROCESSOR ADDR: 1
Theabove parameterswill varydepending upon howyour G4LC32has beenconfigured.The HOSTPORT isthe port
on the G4LC32 used to communicate with a remote PC running Cyrano 200 or OptoControl. The factory default
setting for HOST PORT is COM0.
ThePROCESSORADDR is the address assigned to the G4LC32. The factory default address is 1.
PressENTER to continue viewing the setup parameters.The next display will be similar tothe following:
COM0: 38.4 K
COM1: 115.2 K
COM2: 115.2 K
COM3: 115.2 K
Theabove parameters will varydepending upon how your G4LC32has been configured.
PressENTER to view the next display. Thenextdisplay will be similar to the following:
PROCESSOR IS IN
NONAUTOBOOT MODE
PROCESSORWILL
RUN FROM RAM
Theabove parameterswillvary dependingupon how yourG4LC32 has beenconfigured. The factorydefault for the
Autoboot Option is NONAUTOBOOT and the processor to RUN FROM RAM.
PressENTER to view the next display.
PROCESSORWILL
BOOT TO - KERNEL
CONFIGURATION
3-5

G4LC32 User’s Guide
The above parameters will vary depending upon how the G4LC32 has been configured. The factory default is
BOOT TO - KERNEL.
Theabovedisplayisthelast display for the setup parameters. Press ENTER to get out of the SETUP MODE.
Change Mode
Fromthis mode youcanchange any orallof the G4LC32setupparameters. The firstdisplaythat you getwhen you
enter the CHANGE MODE will be the following:
CHANGE MODE:
<î> <Ä> TO SELECT
<ENTER>TOACCEPT
<ESC> TO EXIT
The“<î><Ä> TO SELECT”prompt tells you thatyou can usethe left arrow keyor the rightarrowkey on thetop row
ofthe keyboard tochange parameters whenyou are promptedfora selection. The“<ENTER> TO ACCEPT”prompt
meansthatyoushouldpress theENTER key onthe keyboardafteryou havemade yourselection forthe parameterthat
you are changing. The “<ESC> TO EXIT” prompt means that any time you press the ESC key on the keyboard, the
CHANGE MODE will be terminated and you will be returned to your starting display.
Passwords
Press ENTER toget to the next display. Thedisplaywill read:
ENTER PASSWORD
Thereare three levelsof passwords thatyou can enter,LEVEL 1, LEVEL2 and LEVEL3. The LEVEL3password is the
highestlevel. LEVEL 1 is the lowest. From the above prompt, youmust enter a LEVEL 3 password. Otherwise, you
cannotchange anyof thesetup parameters. Theother levelsof security,LEVEL 2and LEVEL1, areusedwith Cyrano
200 or OptoControl. They are used with the terminal task to prevent unauthorized personnel to change selected
setpoints,etc.
Allpasswordsare sixdigits inlength. Onlythe numericcharacters 0through9areallowed. Ablank isconsidered the
sameas a zero. Thus if you enter 98and then press the ENTER key toACCEPT,the password is interpreted to be the
same as 980000. The factory default password is 000000. Do not forget your password; without it you cannot
changeany parameters! If you enter an invalidpassword, you will get a display promptsimilarto the following:
ENTER PASSWORD
122
INVALID PASSWORD
Ifyou get this prompt,you can just re-enter yourpassword or you canpressthe ESC key tostartfrom the beginning.
Afteryou have correctly entered your LEVEL3password, you will get the followingdisplay:
LEVEL 3 PASSWORD
ACCEPTED
CONFIGURATION
3-6