Wenglor ZAG45FN01 User manual

Operating Instructions
Fieldbus Gateway Fast Ethernet V. 1.3
ZAG45FN01
ZUB-CD-FB

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Index
1. Information on CE marking of the module ........................................................................................... 5
1.1 EU Directive EMC ............................................................................................................................................................ 5
1.2 Scope of application........................................................................................................................................................ 5
1.3 Note installation guidelines ............................................................................................................................................. 5
1.4 Installation of the unit ..................................................................................................................................................... 5
1.5 Working on switch cabinets ............................................................................................................................................ 5
2. Information for the machine manufacturers......................................................................................... 5
2.1 Introduction...................................................................................................................................................................... 5
2.2 EU Machinery Directive .................................................................................................................................................. 5
3. Introduction ............................................................................................................................................ 6
3.1 Fieldbus Gateway software flow-chart ............................................................................................................................ 6
3.2 Fieldbus Gateway application diagram .......................................................................................................................... 7
4. Operation modes of the Gateway.......................................................................................................... 7
4.1 Configuration mode (config mode)................................................................................................................................. 7
4.2 Test mode ........................................................................................................................................................................ 7
4.3 Data exchange mode ...................................................................................................................................................... 8
5. RS-interface............................................................................................................................................ 8
5.1 RS-interfaces at the Fieldbus Gateway ........................................................................................................................... 8
5.2 RS232 Baud Rate ............................................................................................................................................................ 8
5.3 Buffer sizes at the Fieldbus Gateway.............................................................................................................................. 8
5.4 Framing Check ................................................................................................................................................................ 8
6. SSI-interface........................................................................................................................................... 9
6.1 Initiation of the SSI-interface ........................................................................................................................................... 9
6.2 Hardware-wiring ............................................................................................................................................................. 9
7. The Debug-interface ............................................................................................................................ 10
7.1 Overview of the Debug-interface................................................................................................................................... 10
7.2 Starting in the Debug-mode.......................................................................................................................................... 10
7.3 Communication parameter for the Debug-interface ..................................................................................................... 10
7.4 Possibilities with the Debug-interface ........................................................................................................................... 10
7.5 Commands of the Debug-interface............................................................................................................................... 10
8. Mode of operation of the system ........................................................................................................ 10
8.1 General explanation ...................................................................................................................................................... 10
8.2 Interfaces ....................................................................................................................................................................... 10
8.3 Data exchange............................................................................................................................................................... 10
8.4 Possible data lengths .................................................................................................................................................... 10
8.5 Startup phase ................................................................................................................................................................ 10
9. Generating a Script .............................................................................................................................. 11
9.1 What is a Script?............................................................................................................................................................ 11
9.2 Memory efficiency of the programs .............................................................................................................................. 11
9.3 What can you do with a Script device?......................................................................................................................... 11
9.4 Independence of buses................................................................................................................................................. 11
9.5 Further settings at the Gateway .................................................................................................................................... 11
9.6 The use of the Protocol Developer................................................................................................................................ 11
9.7 Accuracies of the baud rates......................................................................................................................................... 12
9.8 Script processing times................................................................................................................................................. 12
10. Implemented protocols in Fieldbus Gateway with ......................................................Universal Script
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10.1 Protokoll: Transparent ................................................................................................................................................... 13
10.1.1 Data structure ................................................................................................................................................................ 13
10.2 Protocol: Universal 232 ................................................................................................................................................. 13
10.2.1 Data structure ................................................................................................................................................................ 14
10.2.2 Fieldbus parameters...................................................................................................................................................... 14
10.2.3 RS-232 parameter table ................................................................................................................................................ 14
10.2.3.1 Start character (232 Start character)............................................................................................................................. 14
10.2.3.2 Length 232 (232 Length) ............................................................................................................................................... 14
10.2.3.3 Data Area ....................................................................................................................................................................... 14
10.2.3.4 End character (232 End character)............................................................................................................................... 14

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10.2.4 Communication sequence ............................................................................................................................................ 14
10.3 Protocol: 3964(R) .......................................................................................................................................................... 15
10.3.1 Data structure 3964R..................................................................................................................................................... 15
10.3.2 Protocol definitions........................................................................................................................................................ 15
10.3.3 Data communication .................................................................................................................................................... 15
10.3.3.1 Initiation of data communication by the low-priority user............................................................................................. 15
10.3.3.2 Conflicts ........................................................................................................................................................................ 15
10.3.3.3 Timeout times ............................................................................................................................................................... 15
10.3.3.4 Retries ........................................................................................................................................................................... 16
10.3.3.5 Initiation of data communication by the high-priority user ........................................................................................... 16
10.3.4 Protocol type 3964 ........................................................................................................................................................ 16
10.4 Protocol: MODBUS-RTU ............................................................................................................................................... 16
10.4.1 Notes.............................................................................................................................................................................. 16
10.4.2 Fieldbus Gateway as MODBUS-Master ........................................................................................................................ 16
10.4.2.1 Preparation ................................................................................................................................................................... 16
10.4.2.2 Data structure ................................................................................................................................................................ 16
10.4.2.3 Communication sequence ........................................................................................................................................... 16
10.4.3 Fieldbus Gateway as MODBUS-Slave .......................................................................................................................... 17
10.4.3.1 Preparation .................................................................................................................................................................... 17
10.4.3.2 Data structure ................................................................................................................................................................ 17
10.4.3.3 Communication sequence ............................................................................................................................................ 17
10.4.4 Fieldbus Gateway as Modbus-ASCII Master ................................................................................................................ 17
10.5 The trigger byte ............................................................................................................................................................. 17
10.6 The length byte ............................................................................................................................................................. 17
11. Hardware ports, switches and LEDs................................................................................................... 18
11.1 Device labeling .............................................................................................................................................................. 18
11.2 Connectors .................................................................................................................................................................... 18
11.2.1 Connector to the external device (RS-interface)........................................................................................................... 18
11.2.2 Connector supply voltage and DEBUG-interface ......................................................................................................... 19
11.2.3 Ethernet 10/100 BASE/T-connector............................................................................................................................... 19
11.2.4 Power supply ................................................................................................................................................................. 19
11.3 LEDs .............................................................................................................................................................................. 19
11.3.1 LED "(Ethernet) Power".................................................................................................................................................. 19
11.3.2 LED "Link/Act. 10 MB".................................................................................................................................................... 19
11.3.3 LED "Link/Act. 100 MB" ................................................................................................................................................. 20
11.3.4 LED "(Ethernet) State" ................................................................................................................................................... 20
11.3.5 LED "Power"................................................................................................................................................................... 20
11.3.6 LED "State"..................................................................................................................................................................... 20
11.3.7 LEDs (Error No./Select ID) ............................................................................................................................................ 20
11.4 Switches ........................................................................................................................................................................ 20
11.4.1 Termination Rx 422 + Tx 422 (serial interface) ............................................................................................................. 20
11.4.2 Rotary coding switches S4 + S5 (serial interface) ....................................................................................................... 20
11.4.3 Rotary coding switch S6 (optional) ............................................................................................................................... 21
11.5 The Debug cable for Fieldbus Gateway SC.................................................................................................................. 21
12. Error handling ...................................................................................................................................... 21
12.1 Error handling at Fieldbus Gateway.............................................................................................................................. 21
13. Installation guidelines.......................................................................................................................... 22
13.1 Installation of the module .............................................................................................................................................. 22
13.1.1 Mounting........................................................................................................................................................................ 22
13.1.2 Removal ........................................................................................................................................................................ 22
13.2 Wiring............................................................................................................................................................................. 22
13.2.1 Connection systems...................................................................................................................................................... 22
13.2.1.1 Power supply ................................................................................................................................................................. 22
13.2.1.2 Equipotential bonding connection................................................................................................................................ 22
13.2.2 Ethernet communication interface ................................................................................................................................ 22
13.2.3 Line routing, shield and measures to combat interference voltage ............................................................................. 22

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Disclaimer of liability
We have checked the contents of the document for conformity with the hardware and software described. Nevertheless, we are
unable to preclude the possibility of deviations so that we are unable to assume warranty for full compliance. The information
given in the publication is,
however, reviewed regularly. Necessary amendments are incorporated in the following editions. We would be pleased to receive
any improvement proposals which you may have.
Copyright
Copyright (C) wenglor sensoric gmbh 1997 – 2009. All rights reserved.
This document may not be passed on nor duplicated, nor may its contents be used or disclosed unless expressly permitted.
Violations of this clause will necessarily lead to compensation in damages. All rights reserved, in particular rights of granting of
patents or registration of
utility-model patents.
13.2.4 General information on line routing .............................................................................................................................. 23
13.2.4.1 Shielding of lines ........................................................................................................................................................... 23
14. Representation of the data in Ethernet-TCP/IP .................................................................................. 24
14.1 Network-addresses, network-connections.................................................................................................................... 24
14.2 TCP-connection setup ................................................................................................................................................... 24
14.3 Data exchange............................................................................................................................................................... 24
14.3.1 TCP or UDP? ................................................................................................................................................................. 24
14.4 Data exchange mode .................................................................................................................................................... 24
14.4.1 Direct data exchange .................................................................................................................................................... 25
14.4.2 MODBUS-TCP ............................................................................................................................................................... 25
14.4.3 E-mail ............................................................................................................................................................................ 25
14.4.4 Server............................................................................................................................................................................. 25
14.4.4.1 Webserver...................................................................................................................................................................... 25
14.4.4.2 FTP-server...................................................................................................................................................................... 25
14.4.4.3 File system..................................................................................................................................................................... 25
15. Technical data ...................................................................................................................................... 26
15.1 Device data ................................................................................................................................................................... 26
15.1.1 Interface data ................................................................................................................................................................ 27
16. Commissioning guide.......................................................................................................................... 28
16.1 Note ............................................................................................................................................................................... 28
16.2 Components.................................................................................................................................................................. 28
16.3 Installation ..................................................................................................................................................................... 28
16.4 Dimensional drawing Fieldbus Gateway - Fast Ethernet.............................................................................................. 28
16.5 Commissioning.............................................................................................................................................................. 28
16.6 Ethernet connection ..................................................................................................................................................... 28
16.7 Connection to the process device ................................................................................................................................ 28
16.8 Shield connection.......................................................................................................................................................... 29
16.9 Connecting the supply voltage ..................................................................................................................................... 29
17. Servicing............................................................................................................................................... 29
17.1 Returning a device......................................................................................................................................................... 29
17.2 Downloading PC software............................................................................................................................................. 29
18. Annex ................................................................................................................................................... 30
18.1 Hexadecimal table......................................................................................................................................................... 30

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1. Information on CE marking of the module
1.1 EU Directive EMC
The following applies to the module described in this User Manual:
Products which bear the CE mark comply with the requirements of EU Directive „Electromagnetic Compatibility“ and the harmo-
nized European Standards (EN) listed therein.
The EU Declarations of Conformity are available at the following location for perusal by the responsible authorities in accordance
with the EU Directive, Article 10:
wengor sensoric gmbh, wenglor Straße 3, DE-88069 Tettnang
1.2 Scope of application
The modules are designed for use in the industrial sector and comply with the following requirements.
Scope of
application
Requirement applicable
to Emitted interference
Requirement applicable
to Interference immunity
Industry EN 55011 Kl. 1 EN 61000-6-2
1.3 Note installation guidelines
The module complies with the requirements if you
1. comply with the installation guidelines described in the User Manual when installing and operating the module.
2. also follow the rules below on installation of the equipment and on working on switch cabinets.
1.4 Installation of the unit
Modules must be installed in electrical equipment rooms/areas or in enclosed housings (e. g. switch boxes made of metal or
plastic). Moreover, you must earth the unit and the switch box (metal box) or at least the top-hat rail (plastic box) onto which the
module has been snapped.
1.5 Working on switch cabinets
In order to protect the modules against static electrical discharge, the personnel must discharge themselves electrostatically
before opening switch cabinets or switch boxes.
2. Information for the machine manufacturers
2.1 Introduction
The Fieldbus Gateway module does not constitute a machine as defined by the EU "Machinery“ Directive. Consequently, the
module does not have a Declaration of Conformity in relation to the EU Machinery Directive.
2.2 EU Machinery Directive
The EU Machinery Directive stipulates the requirements applicable to a machine. The term "machine" is taken to mean a totality of
connected parts or fixtures (see also EN 292-1, Paragraph 3.1)
The module is a part of the electrical equipment of the machine and must thus be included by the machine manufacturer in the
Declaration of Conformity process.

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3. Introduction
The Fieldbus Gateway Fast Ethernet module serves to adapt a serial port to Ethernet networks. The terminal unit’s protocol is
converted in the Fieldbus Gateway via a Script.
The module CL-Fast Ethernet essentially consists of the following hardware components:
•Electrically isolated 10/100 Base-T-interface to Ethernet
•Ethernet controller W3100A and REALTEK RTL8201CP
•Microprocessor 89C51 RD2
•RAM and FLASH
•Optionally electrically isolated on the RS-side
•Serial interface (RS-232, RS-485 and RS-422) to the device connected externally
3.1 Fieldbus Gateway software flow-chart
HW Reset
RAM test
Konfigmode
Switch = FF
?
j
j
j
n
Init
Start konfig msg
Read/write konfig data
Appl.
Testmode
Switch = EE
?
n
n
Test
Debugmode
Start test msg
Testmode
Debugmode

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3.2 Fieldbus Gateway application diagram
The following graph shows a typical connection scheme.
4. Operation modes of the Gateway
4.1 Configuration mode (config mode)
The configuration mode serves to configure the Gateway. The following adjustments are possible in this mode.
•Loading a Script (e. g. by means of the software WINGATE with "Write Script" under "File")
•Updating the firmware (e. g by means of the software "FDT")
•Configuration of the Gateway (by means of the software WINGATE)
The Gateway will be starting in this mode in case both switches S4 as well as S5 are set on position "F" when switching on the
Gateway. Right after switching on the Gateway in the configuration mode it will be sending its starting message, that looks analog
with the following message:
"RS-FE-CL (232/422/485) V3.0 [29] (c)dA Switch=0xFF Script(8k)="Leer" Author="wenglor sensoric gmbh" Version="1.0"
Date=21.08.2001 SN=47110001 IP=0.0.0.0“.
In the configuration mode the Gateway always operates with the settings 9600 Bauds, no Parity, 8 Databits and 1 Stopbit, the
RS-State LED will always be flashing red, the "Error No/Select ID" LEDs are of no account for the user. All software revisions
contain the configuration mode.
4.2 Test mode
Setting of the test mode
The test mode is set by bringing the switches S4 and S5 in position "E". All other switches will not be taken into consideration for
the setting of the test mode. Now the Gateway has to be restarted with these settings (by a short disconnection from the power
supply).
In the test mode the Gateway always operates with the settings 9600 baud, no parity, 8 databits and 1 stopbit.
The test mode may be helpful to integrate the Gateway in the relevant environment, for instance to test the parameters of the
RS-interfaces.
Mode of operation of the test mode
After the restart in the test mode the Gateway will be sending the values 0…15 in hexadecimal representation ("0"…"F") in ASCII-
coding on the serial side every second. Simultaneously the same values are issued binary on the fieldbus-interface.
In this mode the State-LED on the RS-side will be flashing red, the "Error No/Select ID" LEDs will be displaying the value in a
binary way, that is issued that moment. Additionally each character that is received at one of the interfaces will also be output at the
same interface as a local echo. On the fieldbus-side only the first byte will be used for the local echo, that means on receiving as
well as on transmitting only the first byte of the bus data is looked at, the other bus data do not change compared to the last data.
24 V
RS-232
RS-485
RS-422 Fieldbus Gateway
Debug
RS-232
Industrial
Ethernet
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4.3 Data exchange mode
The Gateway has to be in the data exchange mode, so that a data exchange between the RS-side of the Gateway and the field-
bus is possible. As long as the Gateway is not in the configuration mode or the test mode, the data exchange mode is active. In
the data exchange mode the Gateway will execute the downloaded Script with the parameters, that have been preset through
WINGATE.
5. RS-interface
5.1 RS-interfaces at the Fieldbus Gateway
The Fieldbus Gateway - Fast Ethernet has the interfaces RS-232, RS-422 and RS-485 available. The hardware always features a
DEBUG-interface, see chapter 7.
5.2 RS232 Baud Rate
The baud rate for the RS 232 port can be set by means of the rotary selector switches. Transmission takes place with the para-
meters 8N1.
Schalterstellung Baudrate
1 115,2 k
2 57,6 k
3 38,4 k
4 19,2 k
5 9,6 k
6 4,8 k
Baud Rate
5.3 Buffer sizes at the Fieldbus Gateway
Fieldbus Gateway CL features at the serial side a buffer with the size of 1024 bytes for input data and output data each.
The FIFO of the application interface (RS-interface) can be changed in any Gateway form Script revision 26 on, that is capable for
Script. For it please check in the Protocol Developer under "Device Control" - "Hardware".
5.4 Framing Check
The length of the stop bit received by the Gateway is checked through the function "Framing Check". Here the stop bit generated
by the Gateway is always long enough, so that connected participants can evaluate the stop bit.
Please be aware that the function "Framing Check" becomes effective only in case of 8 data bit and the setting "No parity".
An error is detected and indicated by the Error LEDs in case the stop bit does not show the length 1 bit during the activated check.
The possible setting for this parameter can be controlled by the Script (see online help from Protocol Developer). The presetting
for the "Stop Bit Framing Check" is "enabled".

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6. SSI-interface
The Fieldbus Gateway also supports the connection of applications or products, that communicate via SSI.
6.1 Initiation of the SSI-interface
The required Script (example_SSI), the firmware- (Cust0023) and Protocol Developer-extension (Cust_ssi.xml) are available free
of charge from our website at www.wenglor.com, as well as the softwaretool Protocol Developer and the configuration software
WINGATE.
•In the Protocol Developer (see chapter 7, The Debug-interface) the ConfigFile "Cust_ssi.xml" has to be added. At Options 
Settings ConfigFiles.
•Load the Script "example_SSI.dss" into the Protocol Developer.
•The encoder type has to be defined in the Script itself under "Set number of bits" and "Set typ" (default = 12-Bit-Single-Turn-
Gray):
/// Set number of bits (1..16 = Single Turn, 17..32 = Multi Turn)
moveconst (bAnzBit, 12); // i. e. 12 Bit single turn
// Set typ
// Values of bTyp:
// 0 = Reserved
// 1 = Output-value without change (i. e. binary encoder)
// 2 = Output-value changed from Gray to Binary (i. e. Gray encoder)
// >2 = Reserved
moveconst ( wTyp, 2); // i. e. 12 Bit Gray
•Load the Script into the device. Open WINGATE and activate the device in the configuation mode (see chapter 4.1, Configurati-
on mode (config mode)) - an actuation message appears, that looks in line with the following (example CL-PB):
•Special Firmware (23) not loaded
•RS-PBV1-CL (232/422/485) V7.31[30] (c)dA Switch=0x02FF Script(8k)="SSI" Author="wenglor sensoric" Version="V 1.0"
Date=20.03.2008 SN=47110002 ID=2
•Konfigmode…
•The note "Special Firmware (23) not loaded" means that the firmware-extension is not yet loaded. The extension is loaded
through Extras Firmware Script Extension. Select the file "Cust0023 (Cmd 23 + 24 for SSI).hex" and choose "write extensi-
on".
•Re-start the device now only the device’s actual actuation message appears and not the note any more.
•Bring the device into the data exchange mode (see chapter 4.3, Data exchange mode) DONE!
6.2 Hardware-wiring
The clock wires of the SSI-interface are placed onto the Tx-wires of the RS-422-interface and the data wires onto the Rx-wires at
the Fieldbus Gateway.
X1 (3pin + 4pin screw-plug-connector):
Pin no. Name Function at SSI
1 Rx 232 n. c.
2 Tx 232 n. c.
3 AP-GND n. c.
4 RX 422+ SSI DAT+
5 Rx 422– SSI DAT–
6 Tx 422+ SSI CLK+
7 Tx 422– SSI CLK–
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7. The Debug-interface
7.1 Overview of the Debug-interface
The Fieldbus Gateway®IC features a Debug-interface, that allows a step-by-step processing of a Script. Normally this interface is
only required for the development of a Script.
7.2 Starting in the Debug-mode
When applying power to the Fieldbus Gateway®(power up) the firmware will output the binary character 0 (0x00) after a self-test
was carried out on this interface. If the Fieldbus Gateway®receives an acknowledgement via this interface within 500 ms, it is in
the Debug-mode. The acknowledgement is the ASCII-character O (0x4F).
With the start in the Debug-mode the further execution of Script commands will be put to a stop.
7.3 Communication parameter for the Debug-interface
The Debug-interface is always operating with 9600 baud, no parity, 8 data bit, 1 stop bit. It is not possible to change this parame-
ter in the Protocol Developer. Please consider the fact that these settings have to be in accordance with those of the PC-COM-
interface and that the flow control (protocol) has to be set on „none“ there.
7.4 Possibilities with the Debug-interface
Usually the Protocol Developer is connected to the Debug-interface. With it a step-by-step processing of a Script, monitoring
jumps and decisions and looking at memory areas is possible. Moreover breakpoints can be set. It basically possesses all cha-
racteristics a software-development tool is typically supposed to have. However, it is also possible to carry out a Scrip-update via
this interface.
From Script version [27] on you can also output data with the Script command "SerialOutputToDebugInterface". Please also pay
attention to the remark in the manual ’Protocol Developer’.
7.5 Commands of the Debug-interface
The commands for the use of the Debug-interface are described in the instruction manual Protocol Developer.
8. Mode of operation of the system
8.1 General explanation
Communication can be split into seven layers, Layer 1 to Layer 7, in accordance with the ISO/OSI model.
The wenglor sensoric Gateways convert Layers 1 and 2 of the customized bus system (RS-485/RS-232/RS-422) to the correspon-
ding Fieldbus system. Layers 3 and 4 are being covered by the UDP/IP-protocol, TCP/IP-protocol. The Layers 5 and 6 are empty.
Layer 7 is converted in accordance with chapter 8.3.
8.2 Interfaces
The Gateway features the RS-232-, RS-422- and RS-485-interfaces.
8.3 Data exchange
All data is transferred by the Gateway in dependence of the downloaded Script.
8.4 Possible data lengths
The table below shows the maximum transferable data:
Input data max. 1024 bytes Variable: maximum value in this case
Output data max. 1024 bytes Variable: maximum value in this case
8.5 Startup phase
The Master sets up a TCP/IP- or a UDP/IP-connection to the Gateway during the startup phase. Only after a correct termination of
the startup phase the data exchange with external devices will take place.