Seneca Z-KEY User manual

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MI003790
MI003796
SENECA s.r.l.
Via Austria, 26 –35127 –PADOVA –ITALY
Tel. [phone] Fax. [phone]
Web site: www.seneca.it
Technical assistance: supp[email protected] (IT), [email protected] (Other)
Commercial reference: co[email protected] (IT), [email protected] (Other)
This document is property of SENECA srl. Duplication and reproduction are forbidden, if not authorized. Contents of the present
documentation refers to products and technologies described in it. All technical data contained in the document may be modified
without prior notice Content of this documentation is subject to periodical revision.
To use the product safely and effectively, read carefully the following instructions before use. The product must be used only for the use
for which it was designed and built. Any other use must be considered with full responsibility of the user. The installation,
implementation and set-up is allowed only for authorized operators; these ones must be people physically and intellectually suitable.
Set up must be performed only after a correct installation and the user must perform every operation described in the installation
manual carefully. Seneca is not considered liable of failure, breakdown, accident caused for ignorance or failure to apply the indicated
requirements. Seneca is not considered liable of any unauthorized changes. Seneca reserves the right to modify the device, for any
commercial or construction requirements, without the obligation to promptly update the reference manuals.
No liability for the contents of this documents can be accepted. Use the concepts, examples and other content at your own risk. There
may be errors and inaccuracies in this document, that may of course be damaging to your system. Proceed with caution, and although
this is highly unlikely, the author(s) do not take any responsibility for that. Technical features subject to change without notice.
USER MANUAL
Z-KEY
MODBUS ETHERNET SERIAL GATEWAY
AND SERIAL DEVICE SERVER

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Date
Revision
Notes
06/02/2015
00
First revision.
31/03/2015
01
Added Export tag setup Webserver function, added
Seneca discovery and Easy Z-KEY utilities.
08/04/2015
02
Added Glossary.
Added Z-modem protocol issue through internet
Minor fix
14/07/2015
03
Added support for 7 bits Uarts (from SW004100_105)
20/11/2015
04
Added CGI command chapter
18/05/2016
05
Added Gateway Optimzed function from revision
Firmware 4100_108
Added Chapter Easy Setup APP for Android
Added Chapter Seneca Discovery Device
Updated Seneca Device Discovery Chapter
01/12/2016
06
Removed WARNING about using multi TCP Clients in
Bridge mode
02/11/2017
07
Changed PDF title

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Table of Contents
1. GLOSSARY..................................................................................................................7
2. INTRODUCTION...........................................................................................................9
2.1. Features ......................................................................................................................................................... 9
2.2. General Specification ....................................................................................................................................10
3. ELECTRICAL CONNECTIONS..................................................................................11
3.1. Terminal Positions ........................................................................................................................................11
4. DEBUG LEDS.............................................................................................................13
5. DEFAULT CONMFIGURATION .................................................................................14
6. ETHERNET COMMUNICATION.................................................................................15
6.1. Searching Z-KEY devices in a network with the Seneca Discovery Utility.......................................................15
6.2. Changing the IP address from the USB port...................................................................................................16
7. THE EMBEDDED WEBSERVER................................................................................20
7.1. LAN connection to the webserver .................................................................................................................20
8. MODBUS RTU AND MODBUS TCP-IP PROTOCOL ................................................22
8.1. Modbus function code supported .................................................................................................................22
9. BRIDGE MODBUS TCP-IP TO MODBUS RTU..........................................................23
9.1. How it works.................................................................................................................................................24
9.2. Modbus Bridge Webserver configuration......................................................................................................24
10. GATEWAY MODBUS TCP-IP / MODBUS RTU (PORT 1 AND PORT 2 MODBUS
MASTER) ..........................................................................................................................30
10.1. How it works.................................................................................................................................................31
10.2. Modbus Gateway configuration (Port 1 and Port 2 Modus Master) ..............................................................32
10.3. Modbus Gateway Tags Setup, export and import .........................................................................................38

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10.4. Modbus Gateway Real Time view .................................................................................................................41
10.5. Using the Microsoft Excel ™ template for Tags setup ....................................................................................41
11. GATEWAY MODBUS TCP-IP / MODBUS RTU (1 PORT MASTER AND 1 PORT
SLAVE)..............................................................................................................................44
11.1. How it works.................................................................................................................................................44
11.2. Gateway Modbus TCP-IP / Modbus RTU (1 port Master and 1 port Slave) Webserver configuration ............45
11.3. Modbus Gateway Tags Setup, export and import .........................................................................................52
11.4. Modbus Gateway Real Time view .................................................................................................................55
11.5. Import/Export TAGs setup ............................................................................................................................55
12. GATEWAY MODBUS TCP-IP / MODBUS RTU (2 PORT SLAVES) ......................58
12.1. How it works.................................................................................................................................................58
12.2. Webserver configuration Gateway Modbus TCP-IP / Modbus RTU (2 port Slaves)........................................59
12.3. Modbus Gateway Tags Setup, export and import .........................................................................................65
12.4. Modbus Gateway Real Time view .................................................................................................................69
12.5. Using the Microsoft Excel ™ template for Tags configuration........................................................................69
13. REMOTE SERIAL COM PORT ...............................................................................71
13.1. How it works.................................................................................................................................................71
13.2. Remote Serial Com Port Webserver configuration ........................................................................................72
13.3. Seneca Serial to Ethernet Connect ................................................................................................................76
13.3.1. Installing Seneca Serial to Ethernet Connect driver.................................................................................... 76
13.3.2. Select the Com port for Seneca Serial to Ethernet Connect ....................................................................... 80
13.3.3. Configuring Seneca Serial to Ethernet Connect.......................................................................................... 81
13.3.4. Debugging the Connection ......................................................................................................................... 82
13.3.5. Changing the COM port number................................................................................................................. 83
14. THE CUSTOM WEBSERVER.................................................................................88
15. ACCESSING THE Z-KEY FROM INTERNET .........................................................89
16. THE KIT-USB ..........................................................................................................91

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17. THE RS232 DB9 CABLE ........................................................................................91
18. WINDOWS USB DRIVERS INSTALLATION ..........................................................92
19. FIRMWARE UPDATE..............................................................................................94
19.1. Firmware Update from Webserver ...............................................................................................................94
19.2. Firmware Update from FTP server ................................................................................................................94
19.3. Firmware Update from microSD card............................................................................................................94
20. SENECA DISCOVERY DEVICE..............................................................................95
21. EASY SETUP APP FOR ANDROID........................................................................95
22. CGI (COMMON GATEWAY INTERFACE) COMMAND..........................................96

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Seneca Z-KEY
CAUTION!
UNDER ANY CIRCUMSTANCES, SENECA S.R.L. OR ITS SUPPLIERS SHALL NOT BE RESPONSIBLE FOR
LOSS OF RECORDING DATA/INCOMES OR FOR CONSEQUENTIAL OR INCIDENTAL DAMAGE DUE
TO NEGLECT OR RECKLESS MISHANDLING OF Z-KEY, EVEN THOUGH SENECA IS WELL AWARE OF
THESE POSSIBLE DAMAGES.
SENECA, ITS SUBSIDIARIES, AFFILIATES, COMPANIES OF THE GROUP, ITS SUPPLIERS AND
RETAILERS SHALL NOT GUARANTEE THAT THE FUNCTIONS WILL SATISFY COMPLETELY
CUSTOMER’S EXPECTATIONS OR THAT Z-KEY, THE FIRMWARE AND THE SOFTWARE SHALL HAVE
NO ERRORS OR WORK CONTINUOUSLY.

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1. Glossary
Modbus RTU
An open protocol for the serial communications developed by Modicon Inc. (AEG Schneider Automation
International S.A.S.). Simple and robust, it has since become a de facto standard communication protocol.
For more info http://www.modbus.org/specs.php
MODBUS TCP-IP
The Modbus RTU protocol with a TCP interface that runs on Ethernet.
For more info http://www.modbus.org/specs.php
MODBUS BRIDGE
A device that translates, in real time, from Modbus TCP-IP ethernet protocol to Modbus RTU serial
protocol.
MODBUS GATEWAY
A device that translate Modbus TCP-IP protocol to Modbus RTU protocol using a buffered memory (called
shared memory). The shared memory can be accessed by multiple devices through Modbus TCP-IP,
Modbus RTU, Webservers etc… but must be configured. The Modbus Gateways are used for speed-up and
for simplify a Modbus network.
SERIAL DEVICE SERVER (REMOTE COM PORT)
A device that enables devices with an RS-232, RS-422 or RS-485 serial interface to connect to an IP network.
This makes it possible to use Ethernet in place of serial cables, minimizing workstation clutter and also
allowing serial devices to be placed far away from the computers with which they are used. A Serial device
server is virtually transparent to the serial protocol.
MODBUS RTU MASTER-SLAVE
The Master is connected with one or more slaves, the slave waits for an incoming register(s) request from
the master. Only one master is allowed, for overcome this limitation you must use a Modbus gateway.
MODBUS TCP-IP CLIENT-SERVER

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The Client (called Master in Modbus RTU) establishes a connection with the Server (called Slave in Modbus
RTU). The Server waits for an incoming connection from the Client. Once a connection is established, the
Server then responds to the registers queries from the Client.
WEBSERVER
A software that store, process and deliver web pages to clients. Clients web can be PCs, Smartphones, Tablets
with a browser (Chrome, Internet Explorer, Firefox etc…).

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2. Introduction
Z-KEY is a serial device server, a Modbus TCP-IP to Modbus RTU Gateway and a Modbus TCP-IP to Modbus
RTU Bridge, into one product.
Two independent serial ports (one RS485 and a RS232/RS485 configurable port), a Fast Ethernet 10-
100MBits and an USB port are available.
The USB port can be used also like a communication port supporting the Modbus RTU protocol for
configuration purpose.
An internal Webserver is also available for configuration and real time values view, a custom webserver con
be loaded into a microSD card (not supplied).
Z-Key is configurable in 5 different modes:
Bridge Modbus TCP-IP to Modbus RTU
Gateway Modbus TCP-IP to Modbus RTU
Gateway Modbus TCP-IP to Modbus RTU (1 port slave and 1 port Master)
Gateway Modbus TCP-IP to Modbus RTU (2 ports slaves)
Remote Serial COM port
2.1. Features
Fast Ethernet port (10-100 Mbit/s)
Support for Transparent Remote Serial Port, Modbus Gateway, Modbus Bridge
Multiprotocol Gateway, Bridge support: Modbus TCP-IP server protocol (by the fast Ethernet), Modbus
RTU master/slave independent configurable on the NR 2 serial ports (NR 1 RS485, and NR 1
RS232/RS485).
Transparent Ethernet to serial connection with Seneca Ethernet to serial driver connection, no protocol
dependent.
Internal webserver for complete configuration
Up to 8 simultaneous client Modbus TCP-IP supported (Bridge or Gateway mode)
Gateway mode: up to 500 Modbus TAG (up to 1000 Modbus registers)
Export/Import Tags setup from Webserver
Export/Import Tags setup to Execel™ template
USB port for changing IP address configuration
Customizable embedded Webserver with CGI support on microSD card
Configurable by Webserver or by USB (Easy setup software)
Replica of the Modbus registers on TCP-IP protocol, Modbus RTU
Baud rate for Modbus RTU: from 1200 baud up to 115200 baud
1500 Vac galvanic isolation between power supply and communication
Quick installation on DIN 46277 rail
Removable screw terminals with section of 2.5 mm2
Firmware update by internal Webserver, FTP server or microSD card

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2.2. General Specification
GENERAL SPECIFICATIONS
Power supply
19.. 28 Vac (50..60 Hz), 11.. 40Vdc
maximum power
consumption
1,2 W
Isolation
1500 Vac
ETHERNET
Ethernet
10 - 100 Mbit/s
Protocol
Modbus TCP-IP
Max connection length
100 m
Connection
RJ 45 on frontal
RS485 COMMUNICATION PORTS
Number
2
Port #1
IDC10 connector (Modbus RTU Master or slave port)
Port #2
Screw terminals 10-11-12 (Modbus RTU Master or slave port)
Baudrate
1200..115200 configurable
Baudrate
1200..115200 configurable
ENVIRONMENTAL CONDITIONS
Temperature
-20 °C.. +50 °C
Humidity
30 ..90% a 40 °C no condensing
Storage temperature
-25..+85 °C
BOX
Dimensions
100 x 17,5 x 111 mm
Box; protection degree
Black, PA6, IP20
CONNECTORS
IDC 10 for Seneca bus
Removable terminals, pitch 5,08 mm
Micro USB
Ethernet RJ45
STANDARDS
EN 61000-6-4/ 2007
Emission, industrial environmental
EN 61000-6-2/ 2005
Immunity, industrial environmental
EN 61010-1/ 2001
Safety

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3. Electrical Connections
For more info please refer to the Installation manual, downloadable from www.seneca.it in the Z-KEY
section.
3.1. Terminal Positions
For power ON Z-KEY, connect the screw terminal 2-3 or use the Seneca BUS for connect the IDC10
connector:
The RS485#1 is available from the IDC10 connector
The RS485/RS232 port #2 is available from the screw terminals 10-11-12:

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For configure port 2 in RS485 mode set the SW2 to OFF:
For configure port 2 in RS232 mode set the SW2 to ON:
Note: before to insert the cable into RJ45 connector, remove the protection rubber:
Micro USB port for a PC connection:

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4. Debug Leds
LED
STATE
MEANING
TX1
FLASHING
Data transmission on RS485
port #1
RX1
FLASHING
Data reception on RS485 port
#1
TX2
FLASHING
Data transmission on
RS485/RS232 port #2
RX2
FLASHING
Data reception on
RS485/RS485 port #2
PWR
ON
Z-KEY is POWERED ON
SD
FLASHING
ACCESSING TO THE SD CARD
ETH TRF
FLASHING
Data traffic on Ethernet port
ETH LINK
ON
Ethernet port connected

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5. Default Conmfiguration
The default configuration is:
IP STATIC: 192.168.90.101
Gateway: 192.168.90.1
Mode: Modbus RTU Bridge on port 1 and port 2
For return to the default configuration:
1) Switch off Z-KEY
2) Move to “ON” all the dip switched:
3) Switch ON Z-KEY
4) Wait 10 seconds
5) Switch OFF Z-KEY
6) Switch OFF all the dip switches:
Now Z-KEY is loaded with the default configuration.

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6. Ethernet communication
The Z-KEY include a fast Ethernet port (10-100Mbit), the TCP-IP integrated protocol supports:
-Static IP address or DHCP
-Gateway support
-Modbus TCP-IP server protocol (support up to 8 Modbus TCP-IP client at the same time)
-Webserver (with user / password protection)
-FTP server (with user / password protection)
The default configuration for the Ethernet port is:
Static IP address 192.168.90.101
Gateway 192.168.90.1
WARNING!
BEFORE CONNECT Z-KEY ON THE NETWORK BE SURE THAT THE IP ADDRESS 192.168.90.101 IT’S NOT
USED BY ANOTHER ETHERNET DEVICE!
WARNING!
DON’T CONNECT MORE THAN 1 Z-KEY WITH THE DEFAULT IP ADDRESS ON THE NETWORK!
6.1. Searching Z-KEY devices in a network with the Seneca Discovery Utility
From the seneca website (www.seneca.it) in the Z-KEY section you can freely download the Seneca
Discovery Utility for obtain the actual Z-KEYs ip addresses in your network.
Click on Search for start the discovery process:

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A list of devices found will be displayed:
6.2. Changing the IP address from the USB port
From the seneca website (www.seneca.it) in the Z-KEY section you can freely download the Seneca Easy
Setup software.
The Z-KEY section launch the EASY Z-KEY Utility for changing or obtaining the Z-KEY actual IP:

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Connect Z-KEY to a PC with a standard micro USB cable, power up the Z-KEY and Click on “TEST” to obtain
the actual IP address:

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For changing the actual IP configuration return to the home page and click on “CONFIGURATION”:
Than click on “Automatic Search”, read the configuration from the Z-KEY than modify the actual
configuration with the new parameters:

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Then click on “send configuration to Z-KEY” button:

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7. The embedded Webserver
The Z-KEY include a Webserver for setup or for view the real time TAGs value.
For Access to the internal webserver type in a browser:
http://192.168.90.101/maintenance/index.html
where 192.168.90.101 is the default ip address.
The webserver can be protected by a user name and a password.
If you are using Internet explorer 9 (or newer) you must enable the compatibility mode (see the arrow
below):
The Z-KEY Embedded Webserver works with the following browser:
-Internet explorer
-Firefox
-Chrome
-Android
-Iphone/Ipad
7.1. LAN connection to the webserver
For connect an Ethernet device to the Z-KEY Webserver you must have the two Ip addresses compatible.