Pyramid Solutions AB7603 User manual

Publication PUB-AB7603-008
BridgeWay
Ethernet to DeviceNet Gateway
User Manual
Part No.AB7603
Pyramid Solutions
1850 Research Drive, Suite 300
Troy, Michigan 48083
Phone [phone]
Web www.pyramid-solutions.com

Table of Contents i
© 2004 Pyramid Solutions Inc. Publication PUB-AB7603-008
Table of Contents
Preface......................................................................... iv
How to Use This Manual ....................................... iv
Important User Information ...................................iv
Related Documentation........................................... v
BridgeWay Module Description.............................1-1
Overview..................................................................... 1-1
Theory of Operation.................................................... 1-2
DeviceNet Features.................................................... 1-3
Ethernet Features....................................................... 1-3
IT-Features................................................................. 1-4
System Requirements................................................ 1-4
Hardware Description................................................. 1-6
Installation................................................................ 2-1
Installation and Operation Requirements................... 2-1
Power and Network Connections............................... 2-2
Connecting Power ...................................................... 2-3
Connecting DeviceNet................................................ 2-4
Connecting to Ethernet............................................... 2-4
Configuration ........................................................... 3-1
Ethernet Network Configuration ................................. 3-1
DeviceNet Network Configuration .............................. 3-8
DeviceNet I/O Configuration..................................... 3-10
Quick Start ............................................................... 4-1
DeviceNet Network Configuration .............................. 4-1
DeviceNet I/O Configuration....................................... 4-8
Ethernet Network Configuration ............................... 4-11
Using the Ethernet File System................................ 4-13
DeviceNet Interface.................................................. 5-1
Network Communications........................................... 5-1
Configuration.............................................................. 5-1
Automatic Baud Rate Detection ................................. 5-1

Table of Contents ii
© 2004 Pyramid Solutions Inc. Publication PUB-AB7603-008
Slave Device Communication..................................... 5-2
Scan Cycles................................................................ 5-2
I/O Message Types .................................................... 5-3
I/O Mapping................................................................ 5-3
Proxy for Group 2 Only Devices................................. 5-3
Run/Idle Mode............................................................ 5-4
Automatic Device Recovery (ADR) ............................ 5-5
Interaction with I/O Tables.......................................... 5-6
EtherNet/IP Interface.............................................. 6-1
Product Features........................................................ 6-1
CIP Objects ................................................................ 6-1
CIP Messaging........................................................... 6-2
Assembly Objects and Connections........................... 6-4
Notes About Using ControlLogix I/O Connections.... 6-10
CIP Bridging ............................................................. 6-11
Modbus/TCP Interface............................................ 7-1
Supported Commands................................................ 7-1
Supported Exception Codes....................................... 7-2
Modbus/TCP Addressing............................................ 7-3
I/O Data Content......................................................... 7-4
I/O Data Format.......................................................... 7-5
File System................................................................ 8-1
File System Conventions............................................ 8-1
Security....................................................................... 8-2
Structure..................................................................... 8-4
Default Files................................................................ 8-5
Virtual File System...................................................... 8-6
System Files............................................................... 8-6
Configuration Files...................................................... 8-7
Password Files......................................................... 8-11
Other Files................................................................ 8-13
BridgeWay Web Page Files...................................... 8-17
IT Functionality ....................................................... 9-1
Default User Accounts................................................ 9-1

Table of Contents iii
© 2004 Pyramid Solutions Inc. Publication PUB-AB7603-008
The FTP Server.......................................................... 9-2
The Telnet Server....................................................... 9-2
HTTP Server............................................................... 9-8
SSI Functionality......................................................... 9-9
Email Client .............................................................. 9-23
Displaying I/O Data on a Web Page......................... 9-24
Status and Diagnostics........................................... 10-1
BridgeWay LEDs ...................................................... 10-1
Diagnostic Web Pages ............................................. 10-4
Status Assembly....................................................... 10-7
Specifications.......................................................... 11-1
Environmental Specifications ................................... 11-1
EMC Directive Compliance....................................... 11-1
Electrical Specifications............................................ 11-1
Mechanical Specifications........................................ 11-2
I/O Data Sizes .......................................................... 11-2
Connectors.............................................................. 12-1
Power ....................................................................... 12-1
DeviceNet................................................................. 12-2
Ethernet RJ45........................................................... 12-3
Auxiliary RS-232 9 Pin D-Subminiature.................... 12-4
Warranty ................................................................ 13-1
Support ................................................................... 14-1
Technical Product Assistance .................................. 14-1
Contact Information.................................................. 14-1

Preface iv
© 2004 Pyramid Solutions Inc. Publication PUB-AB7603-008
Preface
How to Use This Manual
This manual provides an overview of the BridgeWay Ethernet to DeviceNet Gate-
way. It describes how to configure and operate it.
Important User Information
The data and illustrations found in this document are not binding. We reserve the
right to modify our products in line with our policy of product development. The
information in this document is subject to change and should not be considered as
a commitment by Pyramid Solutions. Pyramid Solutions assumes no responsibil-
ity for errors that may appear in this document
There are many applications of the BridgeWay module. Those responsible for the
use of this device must satisfy themselves that all necessary steps have been taken
to verify an application meets all performance and safety requirements including
any applicable laws, regulations, codes, and standards.
The illustrations and samples in this guide are intended solely for the purpose of
example. Pyramid Solutions does not assume responsibility or liability for actual
use based upon the examples shown in this publication.
DeviceNet is a trademark of Open DeviceVendor Association (ODVA), Inc.
EtherNet/IP is a trademark of ControlNet International LTD.
RSLinx, RSNetWorx are trademarks of Rockwell Software.
MS-DOS and Windows are trademarks of the Microsoft Corporation.

Preface v
© 2004 Pyramid Solutions Inc. Publication PUB-AB7603-008
Related Documentation
Document Name Author Web Page
DeviceNet Specification ODVA www.odva.org
EtherNet/IP Specification ControlNet
International
LTD.
www.odva.org
Modbus/TCP Schneider
Automation www.modicon.com/openbus/index.html
Table 2-1 Related Documentation

Chapter 1 Module Description 1-1
© 2004 Pyramid Solutions Inc. Publication PUB-AB7603-008
BridgeWay Module Description
Overview
The BridgeWay Ethernet to DeviceNet Gateway allows you to seamlessly connect
your Information or Control level networks with your Device level network.
The Ethernet to DeviceNet Gateway provides full DeviceNet Master functionality
allowing connectivity to 63 DeviceNet slaves devices along with an Ethernet
TCP/IP interface that supports IT protocols such as SMTP, FTP, HTTP and con-
trol protocols such as EtherNet/IP and Modbus/TCP.
Examples of BridgeWay Ethernet to DeviceNet applications:
•BridgeWay can be used as a gateway to connect information or control
level networks to device level networks for programming, configuration,
control or data collection. (E.g. Modbus/TCP to DeviceNet)
• BridgeWay can provide router/bridge functionality to connect EtherNet/
IP to DeviceNet.
• BridgeWay can provide an internal web server to allow remote viewing of
data via a web browser and can offer email and file transfer capabilities to
enhance your application.

Module Description 1-2
© 2004 Pyramid Solutions Inc. Publication PUB-AB7603-008
Theory of Operation
The BridgeWay provides centralized data storage, the “PassageWayTM”, for data
that is shared between the DeviceNet and Ethernet networks. Data is placed into
the PassageWay by one network interface, allowing the data to be read through the
other network interface.
The BridgeWay appears as a single device on either network using standard proto-
col mechanisms. No special, or extended, protocol features are required of the
devices on either network to read or write the data flowing through the Passage-
Way; all cross-network activity is transparent to the devices on either network.
Figure 1-1 BridgeWay PassageWay Operation
Ethernet
DeviceNet
PassageWay
Input
Table
Output
Table
Input Data
Output Data
Input Data
Output Data

Module Description 1-3
© 2004 Pyramid Solutions Inc. Publication PUB-AB7603-008
DeviceNet Features
• DeviceNet Master scanner functionality supporting up to 63 DeviceNet
slave devices
• Explicit Messaging and Bit Strobe, Poll, and Change of State (COS) I/O
connections.
• Baud rates of 125, 250, and 500 Kbps.
• Automatic baud rate detection option may be enabled or disabled.
• Automatic Address Recovery can be configured to replace a faulted slave
device with a replacement device at the same MAC ID.
• Configuration Recovery can be configured for slave devices so that a
newly replaced slave can be configured to the same settings of the device
it replaces. Combined with Automatic Address Recovery this feature is
known as Automatic Device Recovery (ADR).
• Transfers 500 bytes Input (IN) and 500 bytes Output (OUT) I/O.
Ethernet Features
• Supports the EtherNet/IP protocol, Adapter Class with I/O Server, Mes-
sage Client, Message Server, and CIP Message Routing.
• Supports the Modbus/TCP protocol with up to 8 simultaneous connec-
tions. Conforms to the Modbus/TCP specification 1.0.
• Features UDP and TCP/IP protocol stack.
• Supports DHCP/Bootp and ARP for IP Address configuration.

Module Description 1-4
© 2004 Pyramid Solutions Inc. Publication PUB-AB7603-008
IT-Features
• The BridgeWay features a flexible file system with two security levels.
The size available for user files is approximately 1.4 Mbyte.
• An FTP server provides easy file management using standard FTP clients.
• A Telnet server featuring a command line interface similar to the MS-
DOS™ environment.
• A a flexible HTTP server (Web server) with Server Side Includes (SSI)
functionality. These are commands to the web server embedded in the
HTML code. This enables the user to access the IN/OUT area using a cus-
tomizeable web page interface.
• Firmware updates of the DeviceNet control portion of the BridgeWay
using the RS232 port and BridgeWay Configuration Tool.
• Email client capability. (The BridgeWay can only connect to mail servers
that do not require a username/password to access. A mail server such as
that used by many internet providers could not be used).
System Requirements
The following hardware and software components are needed to use the Bridge-
Way Ethernet to DeviceNet device.
Required Hardware
• BridgeWay Ethernet to DeviceNet module.
• DeviceNet cabling, power, and devices forming a DeviceNet network.
• Ethernet cabling and power.
• PC or other controller with access to the Ethernet network.
• PC to execute DeviceNet Configuration Software. The DeviceNet slave
devices the BridgeWay communicates with are specified using a
DeviceNet Configuration Software Tool such as RSNetWorx for
DeviceNet from Rockwell Software or HMS AnyBus Net Tool-DN.
• 24 VDC power to the BridgeWay module. (DeviceNet power may be
used.)

Module Description 1-5
© 2004 Pyramid Solutions Inc. Publication PUB-AB7603-008
Optional Hardware
• A PC with a serial RS232 COM port to be used by the BridgeWay Con-
figuration Tool Software for downloading firmware updates.
• RS232 null-modem cable (pins 2 and 3 swapped) from the PC to the
BridgeWay module.
• DIN rail to mount the BridgeWay.
Required Software
• DeviceNet configuration software such as RSNetWorx for DeviceNet to
configure DeviceNet devices and BridgeWay’s DeviceNet operation.
RSLinx version 2.31 or later is required.
Optional Software
• BridgeWay Configuration Tool Software to update BridgeWay’s firm-
ware.

Module Description 1-6
© 2004 Pyramid Solutions Inc. Publication PUB-AB7603-008
Hardware Description
All connections, whether power or fieldbus, to the BridgeWay are made on one
end of the module. Phoenix connectors are provided for power and DeviceNet
connections. A RJ-style connector is provided for Ethernet connection. There is a
9-pin D-Subminiature connector for the auxiliary RS-232 port that is used for
field firmware upgrades. See “Installation” on page 2-1 for more details on the
connectors.
There is an 8 position dip switch on the end of the module that can be used to
select a portion of a default IP address that may be used to permit an intranet con-
nection. See “Ethernet Network Configuration” on page 3-1 for more details on
configuring the IP address using the switches.
On the front of the BridgeWay module are 7 LEDs that are used for status indica-
tion. These LEDs provide visual status for the overall module, the DeviceNet
interface, and the Ethernet interface. See “BridgeWay LEDs” on page 10-1 for
details on how the LEDs are used.
The back of the module has a DIN rail mount to allow the module to be mounted
on a DIN rail.

Chapter 2 Installation 2-1
© 2004 Pyramid Solutions Inc. Publication PUB-AB7603-008
Installation
Installation and Operation Requirements
•Power, input and output (I/O) wiring must be in accordance with Class 1, Divi-
sion 2 wiring methods - article 501-4(b) of the National Electric Code,
NFPA 70 and in accordance with local codes.
•Warning - Explosion Hazard - Substitution of components may impair suitabil-
ity for Class 1, Division 2.
•Warning - Explosion Hazard - When in hazardous locations turn off power
before replacing or wiring modules.
•Warning - Explosion Hazard - Do not disconnect equipment unless power has
been switched off or the area is known to be nonhazardous.
•Terminal tightening torque must be between 5-7 lbs-in (0.5-0.8 Nm).
•For use in Class 2 curcuits only.
•Suitable for surrounding temperature of 65 degrees C maximum.
•Use 60/75 C copper wire only.

Installation 2-2
© 2004 Pyramid Solutions Inc. Publication PUB-AB7603-008
Power and Network Connections
The power and network connections to the BridgeWay are made on the end of the
module. Figure 2-1 indicates the location of each connector.
Figure 2-1 BridgeWay Power and Network Connections
DeviceNet Power Aux RS-232
Ethernet
Ethernet IP Address

Installation 2-3
© 2004 Pyramid Solutions Inc. Publication PUB-AB7603-008
Connecting Power
The power connection is a 2-pin terminal block located on the end of the module.
The female terminal block connector is provided with the BridgeWay. Connec-
tions to be made are illustrated in Figure 2-2.
The BridgeWay requires 24 volts DC power. The module will start immediately
when power is applied (There is no On/Off switch on the module).
Figure 2-2 Power Connection
24VDC Common
24 VDC +

Installation 2-4
© 2004 Pyramid Solutions Inc. Publication PUB-AB7603-008
Connecting DeviceNet
The DeviceNet network connection is a 5-pin terminal block located next to the
power connection on the end of the module. The female terminal block connector
is provided with the BridgeWay. Connections to be made are illustrated in Figure
2-3.
A 120 ohm termination resistor (not provided) may be required for proper net-
work termination. See the DeviceNet Specification for specific rules on
DeviceNet connections and termination.
For information on setting the DeviceNet network configuration (MAC ID, baud
rate, etc.), see “DeviceNet Network Configuration” on page 3-8.
Connecting to Ethernet
The Ethernet connection uses a standard RJ45 connector (not provided). This is
plugged into the socket on the end of the module.
For information on setting the Ethernet IP configuration (IP address, DHCP, etc.),
see “Ethernet Network Configuration” on page 3-1.
Figure 2-3 DeviceNet Connection
(Red) Net Power 24VDC +
(Black) Net Power 24VDC Common
(White) CAN High
(Blue) CAN Low
CAN Shield

Chapter 3 Configuration 3-1
© 2004 Pyramid Solutions Inc. Publication PUB-AB7603-008
Configuration
This chapter describes how the BridgeWay Ethernet to DeviceNet Gateway is
configured. The next chapter walks the reader through the configuration of the
BridgeWay using the commonly available configuration tools.
Ethernet Network Configuration
Several methods may be used to set the IP Address. These methods include;
IP Address Configuration Switch, DHCP/Bootp protocol, web browser, and the
ARP protocol.
Setting the IP Address with the Configuration Switch
If DHCP/BootP is not enabled or a server is not found and the Configuration
Switch is non zero, on power up the value of the switch is used to form an the IP
Address. The switch represents the binary value of the last byte in the 4 byte IP
address. In this case it is n.
IP address: 192.168.1.n
Subnet mask: 255.255.255.0
Gateway address: 0.0.0.0 (No gateway set)
This is a private address and can only be used on a local intranet. In such a case a
Web Browser such as Microsoft’s Internet Explorer can be used to access the
BridgeWay’s web page which allows changing the IP Address, Subnet mask, and
GateWay address settings.

Configuration 3-2
© 2004 Pyramid Solutions Inc. Publication PUB-AB7603-008
DIP Switch Example
The switches are set to 00010100 (20 decimal) (The switch position is shown in
White in the diagram.)
The IP address of the module will be set to 192.168.1.20.
Note: The numbers on the switches on the IP configuration DIP switch do NOT
correspond to bit locations in the address value. In fact, they are reversed. i.e. bit 0
is set by switch 8.
Setting the IP Address Using DHCP/BootP
When DHCP/BootP is enabled and a DHCP or BootP server is found, the IP
address, Subnet mask, and Gateway address is automatically configured by the
DHCP/BootP server. It can be enabled using the BridgeWay’s Settings web page.
Note: The use of DHCP is the default configuration for the BridgeWay as
shipped.
Figure 3-1 IP Configuration DIP Switch

Configuration 3-3
© 2004 Pyramid Solutions Inc. Publication PUB-AB7603-008
Setting the IP Address Using Address Resolution Protocol (ARP)
The module’s IP address can be changed using the ARP command from a PC. The
new IP address will be stored in non-volatile memory. ARP requires the module’s
Ethernet MAC Address that is printed on a label on the back of the module.
Note: ARP cannot be used to change the subnet mask and gateway address of the
BridgeWay. These can be configured using the BridgeWay’s Settings web page.
Switch all 8 switches of the IP Configuration DIP switch to the ON position.
Note: The ARP/Ping capability is disabled unless all switches are ON.
On a PC connected to the BridgeWay on Ethernet bring up an MS DOS™ window
and type:
arp -s <IP address> <MAC address>
The arp -s command will store the IP and MAC addresses in the PC’s ARP table.
Next type:
ping <IP address>
When the Ping command is executed, the PC sends this information to the module
using the MAC address. The module detects that it was addressed with the correct
MAC address and adopts the IP address sent by the PC.
Next type:
arp -d <IP address>
The arp -d will remove the static route from the PC’s ARP table.
Switch all 8 switches of the IP Configuration DIP switch to the OFF position to
disable the feature.
This method can be used to reconfigure a module that has been previously config-
ured, or even to reconfigure modules outside the host’s subnet.

Configuration 3-4
© 2004 Pyramid Solutions Inc. Publication PUB-AB7603-008
Arp/Ping Example:
The following commands will set the IP address of a BridgeWay with MAC
address 00-30-11-02-00-5E to 65.106.34.252.
arp -s 65.106.34.252 00-30-11-02-00-5e
ping 65.106.34.252
arp -d 65.106.34.252