Renu Electronics GWY-800 Series User manual

GWY-800
(HART Gateway)
USER’S MANUAL

COPYRIGHT NOTICE
This manual is a publication of Renu Electronics Pvt. Ltd. and is provided for use by its customers only.
The contents of the manual are copyrighted by Renu Electronics; reproduction in whole or in part, for use other than in
support of Renu Electronics equipment, is prohibited without the specific written permission of Renu Electronics.
SERVICE
If service is required then pack the unit in its original packaging container or, if unavailable, any suitable rigid container.
If a substitute container is used, surround the unit with shock absorbing material; damage in shipment is not covered
bythewarranty.Includealetterwiththeunitdescribingthedifficulty and hardware revision and softwareversion;sendto
thefollowingaddress:
Renu Electronics Pvt. Ltd.
Survey No. 2/6,
Baner Road,
Pune-411045
All returns will be tested to verify customer claims of noncompliance with the product warranty. Improper return
packaging, which makes verification impossible, will void the warranty. If noncompliance is verified and is not due to
customer abuse or the other exceptions described with product warranty, Renu Electronics will, at its option, repair or
replace the Product returned to it, freight prepaid, which fail to comply with the foregoing warranty, provided REPL is
notified of such noncompliance within the one-year warranty period.
ASSISTANCE
This manual is designed to provide the necessary information for trouble-free installation and operation of your new
Gateway product. However, if you need assistance, please call Renu Electronics Pvt. Ltd. at 91-20-27292840 or visit
our web site at www.renuelectronics.com
MANUAL REVISION
If you contact us in refference to this manual, please include the following document number
Name : HART Gateway (GWY-800-B) User’sManual
PartNumber : URML205
Document : UMAN\GWY-800-B\0706
Revision : Revision 0
Revision Number Date Description
Revision 0 13/07/2006

Warranty Certificate
For New product: This product is warranted against defects in materials and workmanship for a period of 12 months
from the date of shipment to Buyer.
For Rectified Products:Any product that will be replaced will have Warranty for 6 months or upto Original Product
Warranty period whichever is greater.
The warranty is limited to repair or replacement of the defective unit at the option of the manufacturer. This warranty is
void if the product has been altered, misused, dismantled, or otherwise abused.
ALL OTHER WARRANTIES, EXPRESSED OR IMPLIED,ARE EXCLUDED, INCLUDING BUT NOT LIMITED TO THE
IMPLIED WARRANTIES OF MERCHANTABILITYAND FITNESS FOR A PARTICULAR PURPOSE.
MAINTENANCE & SERVICE :There are no parts that can be serviced by the user. Service should be performed on a
unit substitution basis only. Do not attempt to remove, replace or service any printed circuit board, components or any
hardware/software related with display product. If problem within the display product occurs, contact the factory for
service information or repair.
NOTE : Renu Electronics Pvt. Ltd. is dedicated to providing complete customer service and customer satisfaction. If you
have any comments or criticisms about how to improve the product features/reliability, Please make a note of the
problem/improvement and notify us. We are always open to new ideas and improvements. So please let us know your
ideas and comments.
IMPORTANT
Gateway Products are intended to be Protocol Converters/Data Sharer devices
that can also take control actions on request of device being connected. It is assumed that
user is well acquainted with the PLC / Inverters / Controllers being used.
Any Mechanical or Electrical Modification to this Unit will
void all Warranties.

Contents
INTRODUCTION 1
1.1 Purpose of this manual 2
1.2 Introduction to Gateway 2
1.3 GWY-800-B Specifications 3
HARDWARE 4
2.1 Dimensional Details and Mounting Instructions 5
2.2 Communication Port Details 6
2.3 LED Status 8
GETTING STARTED 9
3.1 Introduction To HART 10
3.2 Introduction To GWY-800-B 12
3.3 GWY-800-B Operation-Configuration And Communication 12
3.4 Configuration of GWY-800-B (IBM Download) 13
3.4.1 When GWY-800-B can accept configuration 14
GWY-800-B FEATURES 15
4.1 Gateway Modes 16
4.1.1 Master-Master Configuration 16
4.1.2 Master-Slave Configuration 18
4.2 Repeat Cycle 19
4.3 Control Word 19
4.4 Error Indication Bit 20
4.5 Communication Parameters 20
TYPICAL PROJECTS AND APPLICATIONS 21
5.1 Project Setup 22
5.2 Applications 23
CONFIGURATIONSOFTWARE 24
6.1 System Requirements 25
6.2 Installation Instruction 25
APPENDIX 26
A FlexibleApplications 27
B Connection of HART Gateway with the field device 30

Introduction
1
DocNo:UMAN\GWY-800-B\0706
REVISION0
INTRODUCTION
In this chapter. . . .
♦Purposeof this manual
♦IntroductionTo Gateway
♦GWY-800-BSpecifications

Introduction
2
DocNo:UMAN\GWY-800-B\0706
REVISION0
1.1 Purpose of this manual
Thankyoufor purchasing GWY-800-B Product from Renu Electronics Pvt. Ltd..
Theintention of this UserManual is to provideaguide for Safeinstallation,Configuration and operation of
GWY-800-B. Functionality of all the Gateway models is same. Read this User manual thoroughly before
installingand operatingGWY-800-B.
Thisdocumentis based on information available at the time of itspublication.While efforts have been made to be
accurate,the information in this document maynotcover all the details or variationsinhardware or software. Fea-
tures described herein may not be present in all hardwares. Renu Electronics Pvt. Ltd. reserves the right to update
informationin this publication without prior notice.
1.2 Introduction to Gateway
Gatewayis a Protocol Converter/ Datasharer for deviceslikePLCs, inverters (AdjustableSpeed Drives), and other
Controllers.Gateway has two serial portsthatconnect with two differentdevices.These devices share datathrough
Gateway. Gateway communicates with a devicetoget the information required by thedeviceconnected on the other
port.The device that requires data iscalled Destination Device and the devicethatprovides data is called Source
Device.Informationcouldbe,
-value of a PLCregister.
- status of a PLC coil.
-Command from Source Device toDestinationDevice to perform anyactionat the destination end.
ConfigurationOfGateway
Note: Please refer ‘IBM Download’ in section 3.4.

Introduction
3
DocNo:UMAN\GWY-800-B\0706
REVISION0
1.3 GWY-800-B Specifications
Power : +24V DC + 10%, 100mA max
LED’s : 3 LEDs for status indication.
CommunicationPorts : 3Communicationport with
COM1 : RS232 / RS422 / RS485 / CMOS
COM2 : HARTOut
COM3 : RS232(Pass ThroughPort)
OperatingTemperature : 0oto 60oC
StorageTemperature : -20oto80oC
Humidity : 10%to 90% (Noncondensing)
Mounting : DINrail or back panelmounting
Dimensions(DINrail) : 105mm(L)X40mm(D)X51mm(W)
Weight : 125gm approx.
Certifications : CE with UL
Immunity to ESD : Level3asperIEC1000-4-2
Immunityto Transients : Level3asper IEC1000-4-4
Immunityto Radiated RF : Level3as perIEC1000-4-3
Immunityto Conducted RF : Level 3asper IEC1000-4-6
Emissions : EN55011 CISPRA

Hardware
4
DocNo:UMAN\GWY-800-B\0706
REVISION0
HARDWARE
In this chapter. . . .
♦DimensionalDetails and MountingInstructions
♦CommunicationPort Details
♦LED Status

Hardware
5
DocNo:UMAN\GWY-800-B\0706
REVISION0
2.1 Dimensional Details and Mounting Instructions
GWY-800 -B unit can be mounted on a back panel or on a DIN rail or can be left hanging. It comes with a separate
DIN rail plate when it is packed. User will have to attach the DIN rail plate to the unit if it has to be mounted on a
panel or DIN rail. If it has to be left hanging, make sure to screw the cables to the DB9 connectors on the Gateway
unit. DIN rail plate also has the provision to screw the unit to the back panel. Following drawing shows how to attach
the DIN rail plate to the unit:
Followinstructions givenbelow:
1.Attach the DIN rail plate to the unit using the clamps on the DIN rail plate.
2. Pull out the clip of the plate.
3. Put the unit on the DIN rail.
4. Push the clip in to secure the unit on the DIN rail.
GWY-800-B unit is shipped with a separate DIN rail plate which has to be attached to the unit, if needed. User can
use the unit with or without the DIN rail plate. Following sketch shows mounting details of GWY-800-B with the DIN
railplate.
DIN rail
clamp
DIN rail
clip
GWY-800
Slot for
clamp
40

Hardware
6
DocNo:UMAN\GWY-800-B\0706
REVISION0
2.2 Communication Port Details
GWY-800-B has three communication portsCOM1, HARTOUTand PassThrough Port. COM1 port iscompactible
to RS232/ RS422/ RS485; HART OUT is a HART Port and Pass Through Port is a serial RS232 Port. Pinout of
these ports are as shown below:
TX-(RS422/RS485)
DB9 Female
1
5
9
6
+5VDC*
(DO NOT USE)
SignalGround
RX+(RS422/RS485)
RXD(RS232C/CMOS)
TXD(RS232C)
TX+(RS422/RS485)
TXD(CMOS)
RX-(RS422/RS485)
6
8
9
72
4
5
3
1
PLC1 / COM1
*Do not use pin no. 6 of PLC1 / COM1.
HARTPASS THROUGH
CTS
DB9 Female
1
5
9
6
DTS
SignalGround
DSR
RXD
TXD
RTS 6
8
72
4
5
3
2 Pin PBT
HARTOUT
HART Terminal BHART Terminal A

Hardware
7
DocNo:UMAN\GWY-800-B\0706
REVISION0
Pin Name SignalLevel Description
1. TX+ RS422/ RS485 DifferentialTransmit +, alsoreferred asTXA
2. TXD RS232 Transmit
3. RXD RS232/ CMOS Receive
4. RX+ RS422/ RS485 DifferentialReceive +,also referredasRXA
5. GND - Signal Ground common to all signals.
6. +5VDC - DO NOT USE
7. TXD CMOS Transmit
8. TX- RS422/ RS485 DifferentialTransmit -,alsoreferred asTXB
9. RX- RS422/ RS485 DifferentialReceive -,also referredas RXB
Pin Description for COM 1 / PLC 1
User can convert RS485 4 wire + Signal Ground system to a 2 Wire + Signal Ground system by shorting following
signals in the communication cable:
TX+
TX- A
RX+ B
RX-
SG SG
Note: If user has attached shield to Earth on Device end, leave the shield open on Gateway end. If user
has connected shield to Signal Ground on Device end, connect shield to Signal Ground on Gateway end.
A and B are polarity insensitive. Twisted pair cable should be used for Rs485 Network.
Upto 31 Devices can be multi-dropped on RS485 port of Gateway.

Hardware
8
DocNo:UMAN\GWY-800-B\0706
REVISION0
2.3 LED Status
Thereare3 LEDs for status indication.
LEDsstatus:
LED
PLC1 Yellow OFF Nodata receive onPLC port
ON / Flashing COM1 / PLC1 side communication OK
OK Green OFF No Firmware
SlowFlashing IBMDownload
FastFlashing Polling HARTDevices
ON DeviceOK
PASS Yellow OFF Nodata receivedonPass Through Port
THROUGH Flashing Recevingdata on PassThroughPort Port

9
DocNo:UMAN\GWY-800-B\0706
REVISION0
Getting Started
GETTING STARTED
In this chapter. . . .
♦IntroductionTo HART
♦IntroductionToGWY-800-B
♦GWY-800-BOperation

10
DocNo:UMAN\GWY-800-B\0706
REVISION0
Getting Started
3.1 Introduction To HART
HART®Field Communications Protocol is widely recognizedasthe industry standard for digitallyenhanced4-20 mA
smart instrument communication. Use of the technology is growing rapidly, and today virtually all major global
instrumentationsuppliers offer products with HART communication.
TheHART protocol provides auniquelybackward compatible solution forsmart instrument communication asboth4-
20mAanalogand digital communication signals are transmitted simultaneously on the same wiring. HART provides
many benefits promised by field bus, while retaining the compatibility and familiarity of existing 4-20 mA systems.
Analog and Digital communication at the same time:
For many years, the field communication standard used by process automation equipment has been a milliampere
(mA)analogcurrentsignal.Inmostapplicationsthemilliamperesignalvaries within a range of 4-20 mA in propor-
tion to the process variable being represented. Virtually all installed plant instrumentation systems use this interna-
tionalstandardto communicate process variable information.
The HART protocol enables two-way digital communication with smart instruments without disturbing the 4-20 mA
analogsignal.Boththe4-20mA analog and HART digital communication signals can be transmitted simultaneously
over the same wiring. Primary variable and control signal information is carried at the 4-20 mA (if desired), while
additional measurements, process parameters, device configuration, calibration, and diagnostics information is
accessiblethrough theHART protocolover thesame wiresat thesametime. Unlikeother “open”digital communication
technologies for process instrumentation, HART is compatible with existing systems.
These enhanced communication characteristics of this technology are reflected in the protocol name, HART which
standsfor“HighwayAddressableRemoteTransducer”.
About HART Technology:
The HART protocol makes use of the Bell 202 Frequency Shift Keying (FSK) standard to superimpose digital
communicationsignals at a low level on top of the 4-20 mA. Since the digital FSK signal is phase continuous, it does
not interfere with the 4-20 mA signal. A logical “1” is represented by a frequency of 1200 Hz and a logical “0” is
represented by a frequency of 2200 Hz as shown in Figures 1 and 2.
-0.5mA
+0.5mA
Analog Signal
FSK freq:
Logical:
1200 Hz
“1”
2200 Hz
“0”
Simultaneous Analog + Digital Communication
HART uses Frequency Shift Keying to encode digital
information on top of the 4-20 mA analog signal

11
DocNo:UMAN\GWY-800-B\0706
REVISION0
Getting Started
The HART FSK signaling enables two-way digital communication and makes it possible for additional information
beyondjustthenormalprocessvariabletobecommunicatedtoor from a smart field instrument. The HART protocol
communicatesat1200 bits per second without interrupting the 4-20mAsignal and allows a host application (master)
to get two or more digital updates per second from a field device.
4mA
20mA
“1” “0” “0” “1” “1”
“1”
“0”
“1” “0”
Time
HART digital communication signal superimposed on the
4-20 mA analog signal
Digital Signal
Analog Signal

12
DocNo:UMAN\GWY-800-B\0706
REVISION0
Getting Started
3.2 Introduction To GWY-800-B
GWY-800 is a protocol converter as well as the HARTmodem. This converts the HARTdigital signal to a serial
communicationprotocol(e.g.MODBUS).This allows various HART field devices to interface directly with serial
protocol(MODBUS)basedmonitoringandcontrolsystems.Serialprotocolcanbemasterorslave configurable
from the set up software.At the same time it allows to communicate the PC based configuration software with
HARTfield devices. Gateway operates in point to point as well as in multi drop HARTnetwork mode.All HART
processinformation,includingprimary, second, third and fourth process variable datais converted to serial protocol
(MODBUS) and available to the host system. Using the Field Device Status Byte data that is available in HART’s
digitalinformation,thegatewaycantransmit,viaseriallink,diagnosticdataincludingsmartdeviceconfiguration
changed;primaryandnonprimaryvariablesoutoflimits; primary variable analog output fixed; cold start; field
devicemalfunction; and more HART status dataavailable.
GWY-800 has three serial ports; 3 ports; COM1 / PLC1 is compatible to RS232/RS422/RS485/CMOS levels, which
can be connected to device like PLCs, Inverters, HMIs and controllers. “Pass Through Port” is serial RS232 port.
“HARTOUT” port is HART protocol compatible.
GWY-800-B communicates with the HMI using HARTprotocol. This allows gateway to access various process
parametersfromHARTport.Gatewayprovides these parameters to third party serial devices like PLCs, controllers.
The PLC can then make decisions based on the parameters values.
Gateway setup software allows different process parameters to be mapped to any register on the other side PLC/
Device.
MicrosoftWindows®basedconfigurationsoftware,GatewaySetup,helpsusertoconfigure Gateway unit.
‘Configuration’
means making the Gateway unit work as per the system requirements. The complete configuration for a unit is
termed as ‘Project’. Project comprises of device names, Register addresses,condition for block execution etc.
Block may contain information like copy number of words from one device to other device and conditions for copy, if
any.
Gateway transfers data between two devices by execution of blocks.
AftertheProject is defined, Drivers for required devices and Projectshouldbedownloaded. Gateway can now
communicatewiththeHARTdevices and serial devices(e.g. PLC or SCADA).
3.3 GWY-800-B Operation-Configuration And Communication
Gatewaycan communicate withserialand HART devicesusingappropriate cables andconfiguration.Microsoft
Windows®basedconfiguration software,GatewaySetup, configures theGateway unit. ‘Configuration’ meansmaking
the Gateway unit work as per system requirements. In this, user need to configure only “PLC1 / COM1” port and
“HARTOut”port.Complete configuration for a Gateway using the Gateway Setup is termed as a ‘Project’.
Gatewaycan now communicate with the specifieddeviceswithout any change in theGatewayhardware. Tocommu-
nicatewith a device,Gatewayneeds Communication Driversfor the devicesand‘Gateway - Device’communication
cables.
EachDevice has a uniqueand predefined protocol forcommunication.Gateway driver has thisprotocol to communi-
catewith the desired device.Astwo devices areconnectedon Gateway, itrequirestwo drivers for communication
(Serial “Pass through port” (RS232) is just a data transfer part).

13
DocNo:UMAN\GWY-800-B\0706
REVISION0
Getting Started
3.4 Configuration of GWY-800-B (IBM Download)
User MUST download Project, PLC1 driver and HART in Gateway before installing any system using
Gateway. Gateway can accept drivers and configuration dataon COM1port.User needs a special IBM download
cablefor downloading configurationinGateway.All configurations canbe downloaded only formSerial port (Port1).
Theother port is dedicatedforHART.
If any change in the current / working project is made, user must download the changed project in Gateway.
Pindetails of IBM downloadcablefor GWY-800-Bare as follows:
DB9 Male (Gateway) DB9 Female (IBM)
22
33
55
1.Fordownloading Firmware,drivers andproject switch offtheGWY-800-Bunit.
2.PowerON the unit again.
For Master-Master mode:
OK LED is on at power on, it checks if the HART device is attached. If HART device is not attached then it goes in
IBMdownloadmodefor10sec.InIBMdownloadmodeOK LED flashes in slow mode.
While scanning HART device at power on unit will flash the OK LED in fast mode (approx. 15 seconds). So If user
wantto configure the gateway, he/she should disconnect the HARTdevice.
Also after checking the HART device connection, it continuously checks the if device is present on the PLC1/
COM1. Block execution will be started only after both the devices will be present.
For Master-Slave Mode:
OK LED is on at power on, it checks if the HART device is attached. If HART device is not attached then it goes in
IBM download mode for 10 sec. In IBM download mode OK LED flashes in slow mode.
While scanning HART device at power on unit will flash the OK LED in fast mode (approx. 15 seconds).
Onlyin IBM downloadmode firmware, driversand project canbe downloaded.
Atpower on, if OK LED doesnotglow indicating that the downloaded firmware,driversor project CRC are not correct
or either of them is not present.
IMPORTANT NOTE:
AS GATEWAY HAS MULTIPLE SIGNALS ON ITS COMMUNICATION PORTS, IBM CABLE FOR GATE
WAY MUST HAVE ONLY THREE RS232 SIGNALS (TXD, RXD AND GND) AS MENTIONED ABOVE.
9-9 PIN CORE CABLE SHOULD NOT BE USED.
USER CAN FORCE GATEWAY IN THE IBM DOWNLOAD MODE.
1) Power on the gateway unit.
2) Short pins 3 and 4 of PLC1/COM1 port.

14
DocNo:UMAN\GWY-800-B\0706
REVISION0
Getting Started
3) Power off the unit (Keep the pins shorted)
4) And Power on the unit again. This procedure will force the gateway go into the IBM download
mode.
3.4.1 When GWY-800-B can accept configuration
If current driver present for PLC1 port is Master (e.g. Modbus (Gateway as Master)
First, it is checked that whether device is connected on HART Port (fast “OK” LED flashing)
Ifdevice is connected, it continuesnormaloperation
Ifdeviceis not connected, it checks forIBMdownloadmode for 10seconds (slow “OK” LEDflashing).
This sequence continues until either is satisfied.
If current driver present for PLC1 port is Slave (e.g. Modbus (Gateway as Slave)
First, it is checked that whether device is connected on HART Port (fast “OK” LED flashing)
Ifdevice is connected, it continuesnormaloperation
If device is not connected, it checks for IBM download mode for 10sec (slow “OK” LED flashing).
This sequence continues until either is satisfied.

GWY-800-B Features
15
DocNo:UMAN\GWY-800-B\0706
REVISION0
GWY-800-B FEATURES
In this chapter. . . .
♦GatewayModes
♦RepeatCycle
♦ControlWord
♦ErrorIndication Bits
♦CommunicationParameters

GWY-800-B Features
16
DocNo:UMAN\GWY-800-B\0706
REVISION0
Block #1
Block #2
Block #3
Block #4
Block #n
.
.
.
.
.
When Control word is enabled, it decides which block has to be executed by writing a specific data in the control
word.
4.1 Gateway Modes
Gatewayhas two modesofoperation: Master-Master andMaster-Slave. Before explainingthesemodes further
Masterand Slave concept shouldbeexplained.
Master:
Masteris a Device / device driverwhichinitiates communication.
Slave:
Slave is Device / Device driver which processes Master’s query, takes necessary action and responds to the query, if
necessary.
4.1.1 Master-Master Configuration
Inthismodeboth Gateway ports are master in nature and devices connected on these ports are slave. Gateway
portsinitiate communication when theproperGateway-Device communication cable isattached. Data is transferred
in blocks. This transfer can either be a continuous process or as per requirement.Acontrol word (Section 4.3),
presentindevice on either side, enabled fromGatewaySetup Software, can control the block execution.
When control word is disabled, then block transfer is a continuous process.Ablock of data is fetched from one
deviceand transferred totheother device. Theamount of datatobe transferred (Numberof words) dependsonBlock
definition in “Block DefinitionArea” in Configuration Software. One block is executed at a time.Acycle consists of
execution of blocks from #1 to #n.
Execution of blocks is performed as follows,