OPTO 22 G4LC32ISA-LT User Manual
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OPTO 22 G4LC32ISA-LT User Manual

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G4LC32ISA-LT USER'S GUIDE
Form 735-990421 — April, 1999
43044 Business Park Drive, Temecula, CA 92590-3614
Phone: 800-321-OPTO (6786) or 951-695-3000
Fax: 800-832-OPTO (6786) or 951-695-2712
www.opto22.com
Product Support Services:
800-TEK-OPTO (835-6786) or 951-695-3080
Fax: 951-695-3017
E-mail: support@opto22.com
Web: support.opto22.com

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  • Page 1 G4LC32ISA-LT USER’S GUIDE Form 735-990421 — April, 1999 43044 Business Park Drive, Temecula, CA 92590-3614 Phone: 800-321-OPTO (6786) or 951-695-3000 Fax: 800-832-OPTO (6786) or 951-695-2712 www.opto22.com Product Support Services: 800-TEK-OPTO (835-6786) or 951-695-3080 Fax: 951-695-3017 E-mail: support@opto22.com Web: support.opto22.com...
  • Page 2 Specifications are subject to change without notice. Opto 22 warrants all of its products to be free from defects in material or workmanship for 30 months from the manufacturing date code. This warranty is limited to the original cost of the unit only and does not cover installation, labor, or any other contingent costs.

  • Page 3: Table Of Contents

    TABLE OF CONTENTS Welcome ..................... v About the G4LC32ISA-LT ......................... v About This Manual ..........................v Document Conventions ........................vi Introduction....................1-1 Overview ............................... 1-1 I/O Units ............................1-2 Software ............................1-2 Possible Applications ........................1-3 OEM Application ........................1-3 Data Concentrator ........................
  • Page 4 OptoControl Software ........................4-2 Configuring Communications to the G4LC32ISA-LT ............4-2 Configuring I/O for the G4LC32ISA-LT ................4-2 Storing User Strategies into G4LC32ISA-LT flash EEPROM........... 4-3 OptoDisplay and OptoServer Software ..................4-3 Updating the G4LC32ISA-LT Firmware ..................4-4 Troubleshooting ..................A-1 Cable and Connector Specifications ............

  • Page 5: Welcome

    Opto 22‘s graphical control languages (OptoControl and Cyrano) and man-machine interfaces (OptoDisplay and MMI), the G4LC32ISA-LT can be programmed to suit many types of industrial control applications. In addition, the G4LC32ISA-LT has two serial ports, configurable as either RS-232 or RS-485, which may be used to communicate to other serial devices or to I/O units (up to 4,096 points per port.)

  • Page 6: Document Conventions

    Menu commands are sometimes referred to with the Menu Command convention. For example, “Select File Run” means to select the Run command from the File menu. • Numbered lists indicate procedures to be followed sequentially. Bulleted lists (such as this one) provide general information. vi G4LC32ISA-LT User’s Guide...

  • Page 7: Introduction

    ISA backplane. Multiple slave-configured G4LC32ISA-LT processors, each with their own I/O, may be installed in a single PC. As a slave, the only resource the G4LC32ISA-LT needs from the ISA bus to run is power. Thus, you may reset the PC, and the G4LC32ISA-LT will continue to operate.

  • Page 8: I/O Units

    The use of flash technology allows a user to remotely download new kernels offered by Opto 22. This avoids the need to go to the actual G4LC32ISA-LT location to download a new kernel that offers features required for a given application.

  • Page 9: Possible Applications

    INTRODUCTION POSSIBLE APPLICATIONS The following diagrams depict common applications for the G4LC32ISA-LT: a stand-alone OEM application, a data concentrator, laboratory automation testing, and a test station. OEM Application Data Concentrator Figure 1-3: Examples of G4LC32ISA-LT applications G4LC32ISA-LT User’s Guide 1-3...

  • Page 10: Laboratory Testing

    INTRODUCTION Laboratory Testing Test Station Figure 1-4: More examples of G4LC32ISA-LT applications 1-4 G4LC32ISA-LT User’s Guide...

  • Page 11: Basic Architecture

    Program control and host communications are handled by a powerful 32-bit 68020 microprocessor. The G4LC32ISA-LT processor’ s 256 KB of battery-backed RAM and 256 KB flash EEPROM allow you to execute control applications with moderate data collection requirements. The processor is mounted on an ISA bus card and can be plugged into a PC.

  • Page 12: Hardware Diagram

    INTRODUCTION HARDWARE DIAGRAM G4LC32ISA-LT Card Overview Figure 1-6 shows the basic components of the G4LC32ISA-LT as viewed from the front. Figure 1-6: G4LC32ISA-LT as viewed from the front 1-6 G4LC32ISA-LT User’s Guide...

  • Page 13: Quick Start

    QUICK START OVERVIEW This chapter provides a brief explanation of how to get the G4LC32ISA-LT up and running on a PC using a hard-wired RS-485 host port connection to I/O units. If you are installing the G4LC32ISA-LT in an environment that is networked, uses multiple hosts, or uses modems, refer to Chapter 3 for detailed instructions.

  • Page 14: Checking Configuration Jumpers

    QUICK START CHECKING CONFIGURATION JUMPERS The G4LC32ISA-LT is configured by the factory for connection to a host PC’ s ISA bus. Its two serial ports are default-configured for RS-485 communication at 115.2 KBd, and are biased and terminated. The G4LC32ISA-LT’ s default address is 1 and the default communication mode is binary.

  • Page 15: Connecting The Battery

    QUICK START CONNECTING THE BATTERY To save battery power, the G4LC32ISA-LT backup battery is not connected at the factory. Refer to Figure 2-2 to determine a suggested battery location and its connection to the G4LC32ISA-LT. For detailed information on connecting the battery, see Chapter 3, “Connecting the Backup Battery.”...

  • Page 16: Installing The G4Lc32Isa-Lt

    Figure 2-3: Installing the G4LC32ISA-LT into a computer COMMUNICATION TO A HOST PC Communication between the host PC and the G4LC32ISA-LT can be configured and verified using the PC-based graphical flowchart language OptoControl, or the OptoTerm utility, which must be installed on the PC.

  • Page 17: Installation And Setup

    This chapter expands upon the quick start information in Chapter 2 with detailed instructions on installing and configuring the G4LC32ISA-LT. After unpacking the G4LC32ISA-LT, review the packing list in Chapter 2 to ensure that all components are included. You may then proceed through the installation procedures below, as detailed in this chapter: 1.

  • Page 18: Setting Configuration Jumpers

    This section describes these configuration jumpers. Refer to Figure 3-1 for the location of the G4LC32ISA-LT jumpers. Table 3-1 describes the use and default settings of most jumpers. “In” means a jumper is installed and “out” means a jumper is not installed.

  • Page 19: Controller Address Jumpers (Address Df0-Df7)

    Jumper group JP2 configures COM0, and jumper group JP18 configures COM1. Refer to Figure 3-3 for the communication jumper settings. Figure 3-3 shows COM0 configured for RS-485/422 communication, and COM1 configured for RS-232 communication. Figure 3-3: RS-485/422 and RS-232 communication selection jumpers G4LC32ISA-LT User’s Guide 3-3...

  • Page 20: Biasing And Termination Jumpers (B0-B8 And C0-C8)

    INSTALLATION AND SETUP Table 3-1: G4LC32ISA-LT Configuration Jumpers (factory defaults are highlighted below) Jumper(s) Description Position Setting Run from RAM EEPROM/RAM Run from EEPROM Autoboot enabled Auto Autoboot Autoboot disabled Binary Communication ASCII Boot to kernel Boot Loader Boot to loader...
  • Page 21 B6 or C6 Pull-up for IRQ+ B7 or C7 Terminator for IRQ B8 or C8 Pull-down for IRQ- B jumpers are for COM0; C jumpers are for COM1 Figure 3-4: Biasing and termination jumpers schematic G4LC32ISA-LT User’ s Guide 3-5...

  • Page 22: 2-Wire Communication

    INSTALLATION AND SETUP The G4LC32ISA-LT is shipped from the factory with all B and C group jumpers installed. This setting is for a G4LC32ISA-LT in a 2-wire or 4-wire RS-485/422 communication link located at the beginning of the physical link. These jumpers bias and terminate the TX/RX± 2-wire, RX± 4-wire, and IRQ communication lines.

  • Page 23: Connecting The Backup Battery

    *Note: These settings are different than the Windows default settings for COM3 & COM4. CONNECTING THE BACKUP BATTERY The G4LC32ISA-LT uses a RAM backup battery. This 3.6-volt lithium battery features a shelf life of up to 10 years and an operational life of two to five years.

  • Page 24: Installing The G4Lc32Isa-Lt

    Note: Be sure to configure the jumpers and connect the G4BATT32 before installing the card. The general procedure for installing the G4LC32ISA-LT card is as follows: 1. Find an unoccupied 16-bit ISA expansion slot in the computer. 2. Remove the expansion slot cover if one is installed.

  • Page 25: Connecting To A Host Pc, Modem, Or Other Device

    RS-485/422 COM0 and COM1 configured ports may be used as a serial link to connect to Opto 22 I/O units. The G4LC32ISA-LT can be separated by up to 3,000 ft. from I/O units or controllers. (An AC38 repeater enables even longer separation distances.) This is accomplished via a single shielded twisted-pair cable that provides communication over an RS-485/422 serial data bus.

  • Page 26: Wiring

    Use the G4LC32ISA-LT connectors provided and refer to the configuration label for wiring information. The following sections describe wiring for the serial ports found on the G4LC32ISA-LT. Use Tables 3-4 and 3-5 as references for wiring the pluggable, 7-terminal, serial port connectors shown in Figure 3-9:...

  • Page 27: Rs-485/422 Com0 And Com1 Pin Connections

    Figure 3-10 presents an example of RS-232 wiring between a host PC and the COM0 or COM1 port of an G4LC32ISA-LT. Verify that the pin connections on your host PC are the same as those called out in the diagram.

  • Page 28: Rs-485/422 Com0 And Com1

    Figure 3-10: RS-232 wiring to a host PC RS-485/422 COM0 and COM1 4-Wire Mode Using an AC37 If you are using an Opto 22 AC37, refer to Figure 3-11 for wiring details. Figure 3-11: RS-485/422 Wiring to an AC37 using 4-wire mode 3-12 G4LC32ISA-LT User’ s Guide...
  • Page 29 INSTALLATION AND SETUP 2-Wire Mode Using an AC37 The AC37 also supports a 2-wire RS-485/422 connection. Refer to Figure 3-12 for wiring. Figure 3-12: RS-485 Wiring to an AC37 using 2-wire mode G4LC32ISA-LT User’s Guide 3-13...

  • Page 30: Wiring To A Modem (A Dce Device)

    Refer to your modem documentation for detailed wiring information, possible jumper configuration, and initialization setup. You may also wish to refer to Opto 22’ s communication application notes, available through Opto 22’s Bulletin Board Service (see Appendix E for details).

  • Page 31: Connecting To I/O Units

    The built-in RS-485/422 COM0 or COM1 port can be used as a serial link to communicate with digital or analog remote I/O units. One method for doing this is to use an Opto 22 P/N G4IOR I/O remote interface as illustrated in Figure 3-14. This method allows the use of Opto 22 standard I/O equipment (G4 panels, cables, etc.).
  • Page 32 Another method for using the RS-485/422 COM0 or COM1 port as a serial link (remote) is to use an Opto 22 P/N SBTA to install I/O units. This allows you to accommodate your own installation practices, application requirements, and cables. Simply mount your I/O units throughout your installation and daisy chain the communication cable between them.

  • Page 33: Led Indicators

    INSTALLATION AND SETUP LED INDICATORS Seven LEDs are located on the G4LC32ISA-LT (Figure 3-16) and perform the functions displayed in Table 3-6. Figure 3-16: LED indicators on the G4LC32ISA-LT Table 3-6: LED Functions Indication This indicator shows processor status. When the processor is functioning normally, the light stays on.
  • Page 34 INSTALLATION AND SETUP 3-18 G4LC32ISA-LT User’ s Guide...

  • Page 35: Software And Firmware

    G4LC32ISA-LT. For more information about Cyrano, refer to the Cyrano User’s Guide (Opto 22 form 702); for Mistic MMI, refer to the MMI User’s Guide (Opto 22 form 626); and for MDS, refer to the MDS User’s Guide (Opto 22 form 691).

  • Page 36: Optocontrol Software

    Before writing OptoControl strategies for the G4LC32ISA-LT, you must inform OptoControl about the I/O connected to the G4LC32ISA-LT. This means you will first need to decide how many I/O points of each type (digital and analog) are required for your application.

  • Page 37: Storing User Strategies Into G4Lc32Isa-Lt Flash Eeprom

    G4LC32ISA-LT in RAM, downloaded and debugged, and then stored in flash memory. If the G4LC32ISA-LT has been set up to boot automatically from flash memory, the OptoControl strategy stored in flash will be executed upon power up.

  • Page 38: Updating The G4Lc32Isa-Lt Firmware

    Each processor has a boot loader permanently stored into a non-erasable portion of its flash memory. This boot loader enables a user to download a new kernel as Opto 22 makes new kernels available, even if the existing kernel has been lost.

  • Page 39: Troubleshooting

    RUN LED flashes after a Kernel is corrupted or processor Remove Boot Loader jumper so that power failure occurred during has malfunctioned. G4LC32ISA-LT boots to loader. Download flash EEPROM firmware installation. kernel, then reinstall Boot Loader jumper. Run LED is blinking. Controller is malfunctioning.
  • Page 40 TROUBLESHOOTING A-2 G4LC32ISA-LT User’s Guide...

  • Page 41: Cable And Connector Specifications

    Belden P/N 8104 (with overall shield) • Belden P/N 9728 (individually shielded) • Belden P/N 8164 (individually shielded with overall shield) • Manhattan P/N M3477 (individually shielded with overall shield) • Manhattan P/N M39251 (individually shielded with overall shield) G4LC32ISA-LT User’ s Guide B-1...

  • Page 42: G4Lc32Isa-Lt Connectors

    CABLE AND CONNECTOR SPECIFICATIONS G4LC32ISA-LT CONNECTORS The following connector is used for the two serial ports on the G4LC32ISA-LT: Green Pluggable 7-Position Terminal Mini-Plug Green Pluggable 7-Position Terminal Mini-Plug Green Pluggable 7-Position Terminal Mini-Plug Green Pluggable 7-Position Terminal Mini-Plug Green Pluggable 7-Position Terminal Mini-Plug •...

  • Page 43: Product Specifications

    APPENDIX C CHAPTER 2 PRODUCT SPECIFICATIONS Table C-1: G4LC32ISA-LT Product Specifications Item Specification 32-bit Motorola 68020 processor CPU clock frequency 16.67 MHz Memory: 256 KB with battery backup (user programs and data) Flash EEPROM on controller 256 KB (Firmware and user programs) RAM/clock battery 3.6-volt lithium, non-rechargeable...
  • Page 44 PRODUCT SPECIFICATIONS C-2 G4LC32ISA-LT User’s Guide...

  • Page 45: Address Jumpers

    APPENDIX D CHAPTER 2 ADDRESS JUMPERS The G4LC32ISA-LT includes eight address jumpers. To set the jumpers based on a predetermined address, refer to the chart below. Note: Address 0 is reserved and should not be used. For details on accessing and setting these jumpers, see Chapter 3.
  • Page 46 ADDRESS JUMPERS D-2 G4LC32ISA-LT User’s Guide...

  • Page 47: Product Support

    APPENDIX E CHAPTER 2 PRODUCT SUPPORT If you have any questions about this product, contact Opto 22 Product Support Monday through Friday, 8 a.m. to 5 p.m. Pacific Time. Phone: 800-TEK-OPTO (835-6786) 951-695-3080 Fax: 951-695-3017 E-mail: support@opto22.com Opto 22 Web site: www.opto22.com...
  • Page 48 PRODUCT SUPPORT E-2 G4LC32ISA-LT User’ s Guide...

  • Page 49: Index

    AC46 to a host PC or alternate, 3-9 modems, 3-9 modem, 3-9 to 3-16 kernel updating, 4-4 connector key disk, 2-1 primary, 3-9 connector keys, 2-1 Host Port Jumpers, 3-2 Host Words, 1-2 G4LC32ISA-LT User’ s Guide Index-1...
  • Page 50 INDEX Opto 22 Technical Support, E-1 sample applications, 1-3 OptoControl, 1-1, 1-2, 2-4, 3-9, 4-1, 4-2 serial communication cables, to 4-4 B-1 to B-2 configuring communications in, 4-2 serial ports, 3-9 strategies, downloading to Flash wiring, 3-9 to 3-16 EEPROM, 4-3 to 4-4...

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