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OPTO 22 G4LC32SX User Manual

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G4LC32SX USER'S GUIDE
Form 581-071218 — December, 2007
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 G4LC32SX USER’S GUIDE Form 581-071218 — December, 2007 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

    Welcome....................7 About This Manual ......................7 Document Conventions ....................7 Unpacking ..........................8 Chapter 1: G4LC32SX Revised Features ..........9 Chapter 2: Introduction ................ 11 The G4LC32SX Model 200 Controller ................. 11 How A User Application Works ................12 I/O Units ........................12 The G4LC32SX and Controller Software .............
  • Page 4 Firmware Updates ......................45 RAM and Flash EPROMs ....................46 Running from Flash EPROM and Making Changes..........46 Chapter 6: Hardware Specifications ............. 47 G4LC32SX Hardware Specifications ................47 G4LC32SER Hardware Specifications ................48 G4LC32ARC Hardware Specifications ................. 48 4 G4LC32SX User’s Guide...
  • Page 5 Figure 3-6: Autoboot and Host Switches ..............21 Figure 3-7: Baud Rates....................22 Figure 3-8: Mounting the G4LC32SX and Power Supply in a Mistic Panel ..25 Figure 3-9: G4LC32SX Daughter Card Installation..........26 Figure 3-10: Connecting the RAM Backup Battery ..........26 Figure 3-11: Location of EPROMS and RAM .............
  • Page 6 Table 1-1: G4LC32SX Revised Features .................9 Table 1-2: RAM Expansion Options ................10 Table 1-3: EPROM Expansion Options ................ 10 Table 3-1: Bootup Jumper..................... 23 Table 3-2: Communication Mode Jumpers ............... 23 Table 3-3: EPROM Jumpers ................... 23 Table 3-4: RAM Jumper ....................24 Table 4-1: RS-232 Pin Connections................

  • Page 7: Welcome

    Welcome About This Manual This guide includes the following sections: Introduction — Describes and presents the parts included with the G4LC32SX controller and the daughter boards. Chapter 1, “Configuration and Installation”—describes controller settings and installation instructions for the G4LC32SX. Chapter 2, “Communications and Cables”—provides information for making communications cables and gives an overview of the communication modes available on the G4LC32SX.

  • Page 8: Unpacking

    Right angle BNC adapter If any item is missing, contact Opto 22. Product Support If you have any questions, contact Opto 22 Monday through Friday, from 8 am. to 5 pm, Pacific Standard Time at: 951/695-3080 Technical Assistance: 800/835-6786 (TEK-OPTO) Fax: 951/695-3017 8 G4LC32SX User’s Guide...

  • Page 9: Chapter 1: G4Lc32Sx Revised Features

    256 KB, expandable to 1 MB 256 KB, nonexpandable Expansion IMPORTANT: Connectors wired for other Opto 22 controllers may not be compatible with the G4LC32SX. Use the connectors provided and refer to the configuration label for wiring information. G4LC32SX User’s Guide 9...
  • Page 10 = Chips from Intel (N/A from Opto 22). Older chips had a 256K base configuration. = See attached to determine if you have a new style G4LC32/G4LC32SX or old style G4LC32/G4LC32SX. = New controllers are marked with a “1MB RAM installed” sticker.

  • Page 11: Chapter 2: Introduction

    The G4LC32SX Model 200 Controller The G4LC32SX controller is a local processing unit designed to be used in a mistic Model 200 control system. A mistic controller is the combination of a powerful industrial microcomputer, highly intelligent I/O, an amazing new control language and a better idea for industrial packaging.

  • Page 12: How A User Application Works

    The advantage of local I/O is speed (1.4 MHz). The disadvantage is that you are limited to a maximum distance of 200 feet from the G4LC32SX. As many as 139 local I/O units can be connected to one G4LC32SX. You can mix and match both digital and analog I/O units as needed by your application.

  • Page 13: Available Options

    CHAPTER 2: INTRODUCTION Available Options The G4LC32SX features two combination RS-422/485 or RS-232 ports. Two additional RS-422/485 ports and ARCNET are optional. Baud rates from 300 to 115K can be selected. One of the two RS-422/485 or RS-232 communications ports, COM0, is dedicated for communications with the remote PC workstation.

  • Page 14: Basic Architecture

    The G4LC32SX controller’ s 32/16-bit architecture, 256 KB of battery backed RAM and 256 KB Flash EPROM allows you to execute medium control applications with extensive data collection requirements. The heart of the G4LC32SX controller is a 32-bit 68020 microprocessor running at 16 MHz, with a 16-bit external bus.

  • Page 15: G4Lc32Sx Features

    CHAPTER 2: INTRODUCTION G4LC32SX Features Some of the features of the G4LC32SX are as follows: • 32-bit 68020 controller with 16-bit external bus • High-speed 16.67 MHz 68020 operation • Two high-speed (115.2 KBd) serial ports (RS-232 or RS-422/485 ports) •...
  • Page 16 CHAPTER 2: INTRODUCTION 16 G4LC32SX User’s Guide...

  • Page 17: Chapter 3: Configuration And Installation

    CHAPTER 3 Configuration and Installation Diagrams G4LC32SX Controller The following figure shows the outline and mounting dimensions of the G4LC32SX controller. Figure 3-1: G4LCSX Controller G4LC32SX User’s Guide 17...

  • Page 18: Figure 3-2: G4Lc32Sx Inside Panel

    CHAPTER 3: CONFIGURATION AND INSTALLATION Figure 3-2: G4LC32SX Inside Panel 18 G4LC32SX User’s Guide...

  • Page 19: G4Lc32Ser Diagram

    G4LC32SER card in the controller expands its port connections with COM2 and COM3. When referring to the following diagram, remember one port can be either COM0 or COM2 and the other COM1 or COM3. Figure 3-3: G4LC32SER Physical Layout G4LC32SX User’s Guide 19...

  • Page 20: G4Lc32Arc Diagram

    The following diagram shows the LEDs and physical layout of the G4LC32ARC daughter card. Functionally, the G4LC32ARC only operates in the top daughter board slot of the controller with its RS-422/485 serial ports as COM2 and COM3. Figure 3-4: G4LC32ARC Physical Layout 20 G4LC32SX User’s Guide...

  • Page 21: Configuration Switches And Jumpers

    Configuration Switches and Jumpers G4LC32SX Switches Use the switches on the G4LC32SX to make configuration changes. Use the label affixed to the inside of the G4LC32SX front cover as a quick reference for configuration information. Activating Setup Changes Activate configuration changes by powering down and then powering up the controller.

  • Page 22: G4Lc32Ser And G4Lc32Arc Daughter Card Switches

    The choices are 2-wire or 4-wire. The factory default is 4-wire. If you are using the RS-232 serial port (G4LC32SER), set this switch to 4- wire and make sure the TERM YES switch is also set. 22 G4LC32SX User’s Guide...

  • Page 23: G4Lc32Sx Jumpers

    Table 3-3: EPROM Jumpers Flash ROM Type 27C1001 (1 Mb UV EPROM ) (256 KB) 27C4001 (4 Mb UV EPROM ) (1 MB) 29F040 (1 Mb Flash EPROM)( 256 KB) 29F040 (4 Mb Flash EPROM)(1 MB) G4LC32SX User’s Guide 23...

  • Page 24: Installation

    : = Jumper not installed Installation G4LC32SX Installation This section describes a typical installation of the G4LC32SX onto a remote or local Panel 200. Adapt these instructions to fit your application if you have a custom panel. To install the G4LC32SX: 1.

  • Page 25: Figure 3-8: Mounting The G4Lc32Sx And Power Supply In A Mistic Panel

    CHAPTER 3: CONFIGURATION AND INSTALLATION Figure 3-8: Mounting the G4LC32SX and Power Supply in a Mistic Panel G4LC32SX User’s Guide 25...

  • Page 26: G4Lc32Sx Daughter Board Installation

    CHAPTER 3: CONFIGURATION AND INSTALLATION G4LC32SX Daughter Board Installation Figure 3-9: G4LC32SX Daughter Card Installation 4. Connect the battery connector to its mate, as shown in Figure 3-10. Factory packed controllers are shipped with the battery disconnected. The battery is located inside the controller mounted to the base with a Velcro strip.

  • Page 27: Ram And Flash Eprom Installation

    The RAM and EPROMs are found on a circuit board underneath the optional daughter board. You can expand the G4LC32SX’s RAM from 256 KB to 1 MB, and the Flash EPROM size from 256 KB to 1 MB. UV EPROMS are 128 KB and are nonexpandable.
  • Page 28 CHAPTER 3: CONFIGURATION AND INSTALLATION 28 G4LC32SX User’s Guide...

  • Page 29: Chapter 4: Serial Communications

    ARCNET port with a 2.5 Mb/s transfer rate. Optional: COM2 and COM3 The G4LC32SX and remote I/O units can be separated by distances of up to 3,000 ft. (even longer distances with an AC38 repeater). A single shielded twisted-pair of wire provides communications over an RS-422/485 communications network to up to 100 (256 with repeaters) remote I/O units.

  • Page 30: Cables And Connectors

    CHAPTER 4: SERIAL COMMUNICATIONS Figure 4-2: G4LC32SX in Middle of network Figure 4-3: G4LC32SX with >100 Units in Middle of network Cables and Connectors RS-422/485 Cables Shielded, twisted-pair wires are recommended for the communications wiring. Typical wire types are: 1. Two-pair – Individually shielded pairs (2 pair) PVC chrome jacket Belden P/N 9729 (#24 gauge –...
  • Page 31 Used for G4LC32SER, RS-422/485 or RS-232 connections and G4LC32ARC RS-422/485 connections: Manufacturer: Phoenix Contact P/N MC1, 5/7-ST-3, 81 Pluggable 7 Position Terminal Plug Used for G4LC32SX power connections: Manufacturer: Phoenix Contact P/N MVSTBW 2, 5/7-ST-5, 08 G4LC32SX User’s Guide 31...

  • Page 32: Wiring

    CHAPTER 4: SERIAL COMMUNICATIONS Wiring IMPORTANT: Connectors wired for other Mistic 200 controllers may not be compatible with the G4LC32SX. Use the connectors provided and refer to the configuration label for wiring information. The following sections describe wiring for the serial ports found on the G4LC32SER and G4LC32ARC daughter cards.

  • Page 33: Figure 4-5: G4Lc32Sx Rs-232 Fuses

    A + 5 VDC fused source is available on the G4LC32SER daughter card from the RS-232 ports’ pin 1. A maximum 0.5 A load can be drawn through the 1 A rated fuse. The replacement part number for this fuse is Opto 22 P/N FUSE01G4 (Wickman P/N 19373A).

  • Page 34: Connections To A Host Pc

    4-wire Mode Using an AC24AT or AC422AT If you are using an Opto 22 RS-422 card (Model AC24AT or AC422AT), the cable will have a male, 9-pin “D” shell connector at the PC end and a pluggable terminal block on the controller end. The cable is wired as shown in the diagram below.

  • Page 35: Figure 4-7: Rs-422/485 Wiring To Host Pc (2-Wire Mode)

    2-wire Mode Using an AC37 If you are using an Opto 22 AC37, the cable will have a male, 9-pin “D” shell connector at the PC end and a pluggable terminal block on the mistic 1 controller end. The AC37 can be wired to detect interrupts initiated from a brick. Refer to the diagram below for wiring.

  • Page 36: Figure 4-9: Rs-232 Wiring To Host Pc

    Make RS-232 communication connections to a host PC by using the RS-232 terminals on the G4LC32SER daughter board. See the following diagram to connect the G4LC32SX to an AT type host computer. Verify pin connections at the host computer are the same as called out in the diagram.

  • Page 37: Figure 4-10: Connections To Remote Interface (G4Ior)

    CHAPTER 4: SERIAL COMMUNICATIONS Figure 4-10: Connections to Remote Interface (G4IOR) G4LC32SX User’s Guide 37...

  • Page 38: Local Communications

    The local bus is a high speed parallel interface communicating at over 1.4 MB/s and can be up to 200 ft. in length. It connects the G4LC32SX controller to local digital and analog I/O units. Table 4-3: Local I/O Bus Specifications Local I/O Bus Specifications No.

  • Page 39: Wiring

    D2 data line or A2 address D3 data line or A3 address D4 data line or A4 address D5 data line or A5 address D6 data line or A6 address D7 data line or A7 address G4LC32SX User’s Guide 39...

  • Page 40: Arcnet

    ARCNET Overview The G4LC32SXARC daughter board is the ARCNET expansion board for the G4LC32SX and can be used as a host port from the controller. For large, distributed control applications, more than one G4LC32SX controller can be networked on a ARCNET bus.

  • Page 41: Leds

    LEDs G4LC32SX LEDs The group of LEDs seen from the G4LC32SX front panel is a combination of Processor Status LEDs and LEDs from each of the G4LC32SX daughter boards. The installed daughter boards determine which LEDs light up. Figure 4-11: G4LC32SX LEDs...

  • Page 42: G4Lc32Ser Leds

    Table 4-10: G4LC32ARC LEDs Description ARCN ARCNET connection is active Transmit LED for COM2 Receive LED for COM2 IRQ2 Interrupt (IRQ) LED for Com 2 Transmit LED for COM3 Receive LED for COM3 IRQ3 IRQ LED for COM3 42 G4LC32SX User’s Guide...

  • Page 43: Led Functional Descriptions

    Flashes when the controller receives information. Failure to flash could indicate a broken wire or a wrong wire connection. Flashes when the controller is transmitting over the serial port. Failure to flash when transmission is expected could indicate the wrong serial port was selected in the application program. G4LC32SX User’s Guide 43...
  • Page 44 CHAPTER 4: SERIAL COMMUNICATIONS 44 G4LC32SX User’s Guide...

  • Page 45: Chapter 5: Software And Firmware

    CHAPTER 5 Software and Firmware FactoryFloor Software The G4LC32SX is designed to work with Opto 22’s FactoryFloor software. FactoryFloor is an integrated suite of industrial control software applications. OptoControl, the foundation of the FactoryFloor suite, is an intuitive, graphical flowchart-based development environment that lets you develop and debug control applications without knowing computer programming.

  • Page 46: Ram And Flash Eproms

    RAM and Flash EPROMs The G4LC32SX has 256 KB of battery backed RAM and 256 KB of Flash EPROM. Both RAM and the EPROMs can be expanded to 1 MB. Refer to the “RAM and Flash EPROM Installation” section in Chapter 1 for expansion installation instructions.

  • Page 47: Chapter 6: Hardware Specifications

    G4LC32ARC with two full-duplex RS-422/485 serial ports @115.2 KBd and Options: one ARCNET port G4LC32SER with two combined full-duplex, RS-422/485 or RS-232 serial ports @ to 115.2 KBd. NOTE: Operation at or near maximum rated temperature for extended periods of time may adversely affect reliability. G4LC32SX User’s Guide 47...

  • Page 48: G4Lc32Ser Hardware Specifications

    0°C to 70°C Operating temperature: -25°C to 85°C Storage temperature: 5% to 95% Relative Humidity Humidity: 300 – 115.2 KBd (All ports) Baud rate: 2-wire or 4-wire RS-485: 2.5 Mb/s ARCNET transfer rate: 0.1 kg Weight: 48 G4LC32SX User’s Guide...

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