Zlinx 485 Manual Documentation Number: Zlinx485m-1808 www.bb-elec.com www.bb-europe.
Zlinx 485 Documentation Number: Zlinx485m-1808 This product was designed and manufactured in Ottawa, Illinois USA Using domestic and imported parts by International Headquarters B&B Electronics Mfg. Co. Inc. 707 Dayton Road Ottawa, IL 61350 USA Phone (815) 433-5100 -- General Fax (815) 433-5105 Website: www.bb-elec.com Sales e-mail: orders@bb-elec.com -- Fax (815) 433-5109 Technical Support e-mail: support@bb.elec.com -- Fax (815) 433-5104 European Headquarters B&B Electronics Ltd.
Introduction Table of Contents Chapter 1: Introduction................................................................................................ 2 About this Manual ...................................................................................................... 2 Support ....................................................................................................................... 2 Zlinx Product Family ....................................................................................
Introduction Chapter 1: Introduction Thank you for purchasing a Zlinx 485 product! This product has been manufactured to the highest standards of quality and performance to ensure your complete satisfaction. About this Manual This manual has been created to assist you in installing, configuring and using your Zlinx 485 Base module. Please read it carefully and follow the instructions to achieve best results.
Introduction The Zlinx 485 family of products features a selection of operational modes, communications modes, Modbus and I/O combinations. The system is scalable making it easy to start with a few I/O points and build a system with the required I/O-Modbus mix.
Hardware Chapter 2: Hardware Zlinx 485 encompasses a growing family of products including Modbus, Peer-to-Peer, base modules, expansion modules, configuration software and accessories. All modules are built into similar enclosures featuring male local bus plugs and female local bus receptacles on the sides, which allow modules to connect together. Modules are DIN rail mountable and feature removable screw terminal blocks. Zlinx 485 Modules Zlinx 485 systems consist of base modules and expansion modules.
Hardware Base Modules Each Zlinx 485 system is built around a base module. Base modules provide Modbus, digital and/or analog I/O and communicate with other Zlinx nodes. Figure 3. A Typical Base Module Several different combinations of digital inputs (DI), digital outputs (DO), analog inputs (AI) and analog outputs (AO) are available. For example, the ZZ-NA-485 Base module features a combination of two AI’s, two AO’s, two DI’s and two DO’s in a package.
Hardware Figure 4. Base and Expansion Modules Connected Together Programming the Base Module using the RS232 connector The base module has a programming feature that can be used to configure that base module as well as expansion modules. The base module connects to the PC for configuration. Connect a PC through the serial port (COM1 to 16) using the provided RJ45 male to serial (DB9 female) cable. Note: A standard RJ45 to serial (DB9) cable will not work, use only the one supplied Figure 5.
Hardware Indicators, Connectors and Accessories LED Indicators Zlinx 485 Base modules have three LED indicators: a Power LED, a Data LED Local Bus Data LED. and a Expansion modules have two LED’s: a Power LED and a Local Bus Data LED Power LED The Power LED illuminates (red) immediately on power up indicating that DC power is present on the power supply terminals. Data LED The Data LED blinks (green) when data is being transmitted or received, either to an expansion module or another base module.
Hardware Figure 6. Power Supply Connector The Power Supply connector (base modules only) is a two-position removable terminal block located on the top of the unit. Terminal spacing is 3.5 mm. The terminal block accepts solid and stranded wires from 28 AWG to 16 AWG. Please check polarity marking in Figure 8. Refer to the following section for information on Power Supply Requirements. Expansion modules receive power from the base module via the local bus connector.
Hardware Figure 7. Local Bus Connector Location RS-422/485 and I/O connectors for base and expansion modules are removable (plug in) screw terminal blocks located on the front and top of the unit. Terminal spacing is 3.5 mm. Depending on the specific model, the number of terminals may vary. The maximum is 16 terminals (two 8-terminal blocks) for I/O, with an additional 5 terminals for RS422/485 on the base module.
Hardware Figure 8. Zlinx 485 Base Module RS-422/485 Connector RS-422/485 Four-Wire Mode When the Zlinx Base module is configured to operate in RS-422/485 four-wire mode the receive terminals are connected to the transmit terminals of the Modbus device it is communicating with. Its transmit terminals are connected to the receive terminals of the Modbus device it is communicating with. Figure 9.
Hardware Figure 10. RS-485 Two-Wire Connection No jumpers are required to bridge the transmit and receive lines in two-wire mode. RS-232 Connection Connect to RS-232 using the RJ45 jack on the front Base module, using the supplied RJ45 male to serial (DB9 female) cable. Note: RTS is reserved for use by the configuration software only. Asserting RTS during normal operation will result in a communication failure. Disable RTS if your hardware supports it.
Hardware Figure 11. DIN Clip with Spring on a Zlinx 485 Module I/O Options and Characteristics I/O Options The Zlinx 485 family of products features a variety of input and output options.
Hardware Digital Outputs Digital outputs send on/off signals (low or high logic levels) to drive external devices such as indicators, relay coils or the inputs of other equipment such as PLC’s, SCADA, etc. Modules with digital outputs are available with sourcing or sinking drivers. Sourcing (PNP transistor) drivers provide up to 240 mA per output at output voltages up to 30 VDC to connected loads. Sinking (NPN transistor) drivers can sink up to 40 mA per output at voltages up to 48 VDC.
Hardware Figure 12. Typical Digital Input Wiring for Various Input Devices (ZZ-4DID0-DCT Expansion Module) Note: No external power supply wiring is required for Expansion modules DO Wiring The following diagram shows typical connection wiring for modules featuring sourcing (PNP) drivers: Figure 13.
Hardware Figure 14. Typical Digital Output Wiring for Sinking Outputs (ZZ-4DID0-DCT1 Expansion Module) AI Wiring The following diagram shows typical connection wiring for analog inputs: Figure 15. Typical Analog Input Wiring (ZZ9D-NA-MR Base Module) AO Wiring The following diagram shows typical connection wiring for analog outputs: Manual Documentation Number: Zlinx485m-1808 www.bb-elec.com www.bb-europe.
Hardware Figure 16. Typical Analog Output Wiring (ZZ9D-NA-MR Base Module) RTD Wiring The following diagram shows typical connection wiring for RTD inputs. Figure 17. Typical RTD Input Wiring Manual Documentation Number: Zlinx485m-1808 www.bb-elec.com www.bb-europe.
Hardware Figure 18. Relay Wiring The following diagram shows typical connection wiring for Relay outputs. Figure 19. Typical Relay Output Wiring Modbus Mode Configuration The Zlinx 485 Base module can be configured to operate in Modbus Mode. In Modbus mode messages are sent across the physical layer (wiring configuration) from the Zlinx 485 base to the Modbus network. To use Modbus mode successfully, an understanding of the Zlinx 485 memory map assignments is necessary.
Hardware I/O Type DO DI AI AO Figure 20. Modbus Memory Address 00001 to 00112 10001 to 10112 30001 to 30112 40001 to 40112 I/O Memory Areas Table Within these sections, addresses are reserved for all Zlinx 485 modules that may be used. Module Base Expansion 1 Expansion 2 Expansion 3 Expansion 4 Expansion 5 Expansion 6 Figure 21.
Hardware • A maximum of 16 points can be displayed at any one time. Appendix D of this manual contains a list of Modbus I/O assignments for the Zlinx 485. Zlinx 485 Modes of Operation Zlinx 485 systems can operate in Peer-to-Peer or Modbus modes. Peer-to-Peer Mode In Peer-to-Peer mode two Zlinx 485 systems provide full serial I/O functionality. In this mode one Base is configured as the master and the other as the slave. (It does not matter which end of the link is the master and which is the slave.
Hardware Figure 23. Modbus Mode devices may be PLCs, RTUs, DCSs, or other Modbus devices, with links up to 32 nodes per Modbus network Connecting the Hardware With an RS-232 connection, the Zlinx 485 Base module is connected to a Modbus device via a DB-9M connector and an RS-232 cable. If the connected Modbus device is configured as a DTE device, use a straight-through cable. If the connected Modbus device is configured as a DCE device, use a null modem cable.
Hardware Figure 24. Zlinx Base Module 2 wire RS-485 Connections Figure 25. Zlinx Base Module 4 wire RS-232 Connections Manual Documentation Number: Zlinx485m-1808 www.bb-elec.com www.bb-europe.
Modbus Basics Chapter 3: Getting Started Zlinx 485 Installation Zlinx 485 Mounting Zlinx 485 modules are DIN rail mountable. Additional ZZ-DIN1 mounting kits can be purchased for replacement. Each kit includes a DIN clip and spring and four spare screws for the Zlinx 485 enclosure.
Modbus Basics Connecting Zlinx 485 to a PC 1. With power disconnected, connect the Base Module into the PC. [Shall change this diagram] Figure 26. Connecting a PC and Base Module 2. Connect any required expansion modules to the base module. (The male local bus connector on the first expansion module plugs into the female connector on the base module. The second expansion module plugs into the first, etc.) 3.
Modbus Basics Figure 27. Discovery Window During the scan the Progress box displays information about the scanning process. If a device is not found at the most recently successful port it continues to scan through COM ports 1 to 16. The bar graph near the bottom of the window indicates progress. 3. If the device is not found the Progress box displays: The device was not found on any serial port. a. Check the power supply and serial cable connections b. Click the Connect button.
Modbus Basics Figure 28.
Modbus Basics • Hardware version number for each module Configuration Tab The Configuration tab contains fields that allow configuration of: • Communications Modes: Peer-to-Peer Master, Peer-to-Peer Slave, Modbus (and related parameters) Input/Output Tab The Input/Output tab contains: • A tree structure listing input and output types for each module • Input and output configuration options Manual Documentation Number: Zlinx485m-1808 www.bb-elec.com www.bb-europe.
Modbus Basics Chapter 4: Configuration & Operation Zlinx 485 Manager software is used to configure Zlinx 485 hardware. Using Zlinx 485 Manager, the system can be configured to operate in Peer-to-Peer or Modbus modes (receiving Modbus commands and data from a Modbus base module). Digital inputs can be configured to operate in Discrete (on/off) or Frequency Counter modes and analog inputs and outputs are configurable for voltage or current loop operation.
Modbus Basics stored as 1xxxx (coil) addresses; analog inputs are converted to 12 bit binary values and stored in 3xxxx (input register) addresses. To configure the Zlinx 485 for Modbus mode: 1. Select the Configuration tab. 2. Select the Modbus option button. 3. In the Modbus Address box, type the Modbus address to be used. Modbus address 0 is reserved for master systems that do not support broadcasts. The allowable range of Modbus addresses is from 1 to 247. The default Modbus address is 1. Figure 31.
Modbus Basics Peer-to-Peer Mode Settings In Peer-to-Peer mode digital and analog signals can be transferred in both directions across a Zlinx 485 link. For successful communication both base modules must be the same model and all expansion modules must be complimentary (e.g. DI to DO, AI to AO) and arranged in the same order on the Local Bus. One is configured as Peer-to-Peer Master and other is configured as Peer-to-Peer slave. It does not matter which one is configured as master.
Modbus Basics been lost. Lost communication is indicated by the Bus LED’s blinking alternately. The default value of 10 is usually satisfactory. The range of values is 10 to 255. Peer-to-Peer Slave To configure the Zlinx 485 Base Module for Peer-to-Peer Slave Mode: 1. Select the Configuration tab. 2. Select the Peer-to-Peer Slave option button... 3. Set the Peer-to-Peer Slave address from 1 to 255. Please note the Peer-to-Peer Master address must also match. Figure 33.
Modbus Basics An input tree appears listing all base and expansion modules in the system and the inputs available on them. Figure 34. Digital Input Configuration 2. Select the Digital Input to be configured. 3. Select Discrete or Frequency Counter (for the first two inputs only). Do NOT exceed 5 kHz for frequency input. Setting the Digital Mode of either of the first two DI’s to Frequency Mode sets both DI’s on that module to the same mode. Do NOT exceed 5 kHz for frequency input. 4.
Modbus Basics Figure 35. Analog Input Configuration 6. Select the Analog Output to be configured. 7. Select the required Analog Mode (0 to 10 VDC or 0 to 20 mA). If RTD module present then, 1. Select the Input/Output tab. Manual Documentation Number: Zlinx485m-1808 www.bb-elec.com www.bb-europe.
Modbus Basics An input tree appears listing all base and expansion modules in the system and the inputs available on them. 2. Select the RTD to be configured. 3. To increase speed, RTD channels may be turned on or off. If nothing is connected to the RTD channel, then uncheck the Channel Enabled option. 4. Select the RTD type as PT100, PT1000, CU10 depending on your RTD type. 5. Select if you have wired a 2, 3, or 4 wire RTD probe to the input module.
Modbus Basics Sending module parameters to the base module. 3. When the updating process is complete, the Status bar displays the message: The configuration has been sent successfully. Updating Zlinx 485 Firmware From time to time updated firmware may become available for Zlinx 485 modules (from the B&B Electronics website). When the Zlinx 485 Manager software is installed on your computer the Zlinx 485 Updater software is also installed. This can be used to update the firmware in your Zlinx 485 modules.
Modbus Basics 11. Click Connect. 12. Re-apply power to the Zlinx 485 Base module. The Power LED should light up. 13. The Zlinx 485 Firmware Updater window opens and displays a list of the base and expansion modules. 14. On the module list, select the base or expansion module to be updated. 15. In the Firmware Image drop down box, select the image file (.hex). 16. Click the Program button to load the firmware into the module. 17. When all updates are complete, click Exit. 18.
Modbus Basics Chapter 5: Modbus Help Modbus ASCII/RTU Basics The Modbus protocol emerged in the mid-1970s as an early protocol for linking terminals with Modicon PLCs using a master/slave (sometimes called a master/client) relationship. A simple, open, message-based protocol, it caught on quickly and became a defacto standard in the industry. It supports asynchronous point-to-point and multidrop communications and can be used with a variety of serial interfaces (RS-232, RS-422, RS485, modems, etc).
Modbus Basics Hints and Tips A few simple suggestions that may assist you if your system is experiencing problems include: • • • Slowing down the polling rate may be helpful if power cycling doesn’t cure the problem. A common misperception is that every serial network must terminate with a resistor. While this was true of early serial network configurations, it’s typically the wrong answer – call our technical support and verify if you’re an exception, at 815.433.5100 option 3.
Product Specifications Appendix A: Product Specifications Base Module Models: Expansion Module Models: Quick Start guide: Manual: CD-ROM disc: Operating Systems supported: Dimensions: Expansion Feature: Power Indicator: ZZ-NA-485, ZZ-NB-485, ZZ-NC-485, ZZ-ND-485 ZZ-4AI, ZZ-4AO, ZZ-2AI2AO, ZZ-8D0-T, ZZ-8D0-T1, ZZ8DDO-R, ZZ-4DI4DO-DCT, ZZ4DI4DO-DCT1, ZZ4RTD1 Paper copy, PDF available on enclosed CD-ROM disc Available on enclosed CD-ROM disc, and on B&B website Zlinx 485 Manager PDF of Zlinx 485 User Manua
Product Specifications Frequency Input: Two DI inputs per module software selectable as Frequency Counters, 0 to 5 kHz range (do NOT exceed more than 5kHz) Digital Outputs Voltage Range: Open Source: 10 to 45 VDC (for sourcing outputs), 0 toVDC (for sinking outputs) 40 mA per output Analog Inputs/Outputs Ranges: Resolution: 0 to 10 VDC or 0 to 20 mA 12 bit Input Accuracy: 0.15 % full scale reading typical, 0.2 % max Output Accuracy: 0.15 % full scale reading typical, 0.
Product Specifications Resolution: Accuracy @ 25ºC: 0.1 º C across -40 to 85 º C ±0.5ºC typical Accuracy -40 to 85ºC: ±2.0ºC maximum Power Consumption: ZZ-Nx-485 = 1W ZZ-4AI = 1W ZZ-4AO = 1.1W ZZ-2AI2AO = 1.2W ZZ-8DI-DC = 0.4W ZZ-8DO-T = 15.8W ZZ-8DO-T1 = 1.1W ZZ-8DO-R = 3.2W ZZ-4DI4DO-DCT = 8.1W ZZ-4DI4DO-DCT1 = 1.0W ZZ-4RTD1 = 0.4W Operating Temperature: Storage Temperature: -40 to 80°C (-40 to 176 °F) ZZ-8DO-R -40 to 65ºC (-40 to 149 º F) -40 to 85 °C (-40 to 185 °F) Humidity: 10% to 90% R.H.
Dimensional Diagrams Appendix B: Dimensional Diagrams Figure 37. Dimensional Diagram of a Zlinx 485 Base Module Manual Documentation Number: Zlinx485m-1808 www.bb-elec.com www.bb-europe.
Serial Connections Appendix C: Serial Connections RS-232 Pinouts RJ-45F Pin 1 2 3 4 5 6 7 8 Signal RS-232 DCE Signal Ground Signal Ground Receive Data Transmit Data Clear to Send Request to Send Not Used Not used GND GND RD TD CTS RTS ----- ----IN OUT IN OUT ----- Figure 38. RS-232 Connections for RJ45 type plug Note: PIN 4 (RTS) is reserved for the configuration software only. Asserting RTS during normal operation will result in a communication failure.
Serial Connections RJ45 male 1 2 3 4 5 6 7 8 DB9 female 5 5 3 2 7 8 9 9 Signal Name Signal Ground Signal Ground Receive Data Transmit Data Clear to Send Request to Send Not Used Not used Direction ----IN OUT IN OUT ----- Figure 39. RJ45 Male to RS232 female adapter cable RS-422/485 4 Wire Pinouts Signal Name Transmit Data (-) Transmit Data (+) Receive Data (-) Receive Data (+) Signal Ground (COM) Figure 40.
Serial Connections Signal Name DataA (-) DataB (+) Not used Not used Signal Ground (COM) Figure 41. Label TDA(-) TDB(+) RDA(-) RDB(+) COM Direction In/Out In/Out ------- Terminal 1 2 3 4 5 Zlinx 485 Base Module Terminal Block Pin-out for RS-485 Two-Wire Operation Manual Documentation Number: Zlinx485m-1808 www.bb-elec.com www.bb-europe.
Modbus I/O Assignments Appendix D: Modbus I/O Assignments 00001-00112 Discrete Digital Outputs Modbus function codes supported are: Function 1: Read DO Status Function 2: Read DI’s Function 3: Read AO Status Function 4: Read AI’s Function 5: Write to Single DO (firmware v2.
Modbus I/O Assignments Modbus Address 00037 00038 00039 00040 00041 00042 00043 00044 00045 00046 00047 00048 00049 00050 00051 00052 00053 00054 00055 00056 00057 00058 00059 00060 00061 00062 00063 00064 00065 00066 00067 00068 00069 00070 00071 00072 00073 00074 00075 00076 00077 00078 00079 00080 00081 00082 00083 00084 00085 Description EXP-2 Digital Output-5 EXP-2 Digital Output-6 EXP-2 Digital Output-7 EXP-2 Digital Output-8 EXP-2 Digital Output-9 EXP-2 Digital Output-10 EXP-2 Digital Output-11 EXP-
Modbus I/O Assignments Modbus Address 00086 00087 00088 00089 00090 00091 00092 00093 00094 00095 00096 00097 00098 00099 00100 00101 00102 00103 00104 00105 00106 00107 00108 00109 00110 00111 00112 Description EXP-5 Digital Output-6 EXP-5 Digital Output-7 EXP-5 Digital Output-8 EXP-5 Digital Output-9 EXP-5 Digital Output-10 EXP-5 Digital Output-11 EXP-5 Digital Output-12 EXP-5 Digital Output-13 EXP-5 Digital Output-14 EXP-5 Digital Output-15 EXP-5 Digital Output-16 EXP-6 Digital Output-1 EXP-6 Digital Ou
Zlinx 485 Models and Features Appendix E: Zlinx 485 Models and Features Zlinx 485 Base Modules Model Number Module Type Protocols I/O ZZNA-485 Base Modbus, Digital I/O, Analog I/O RS-422/485, RS-232, 2DI, 2DO, 2AI, 2AO sourcing DO’s ZZ-NB-485 Base Modbus, Digital I/O, Analog I/O RS-422/485, RS-232, 4DI, 4DO sourcing DO’s ZZ-NC-485 Base Modbus, Digital I/O, Analog I/O RS-422/485, RS-232, 2DI, 2DO, 2AI, 2AO sinking DO’s ZZ-ND-485 Base Modbus, Digital I/O, Analog I/O RS-422/485, RS-232, 4DI
Zlinx 485 Troubleshooting Appendix F: Zlinx 485 Troubleshooting Problem Data LED and Bus LED intermittently blink Causes • Firmware does not match The firmware for all base modules must match and the firmware for all expansion modules must match. The firmware rev number may be viewed on the information tab of the configuration software. If the firmware does not match, then update the firmware with the Firmware Updater Program. • No Peer-Peer communication link The serial connection is not established.
Terms and Definitions Appendix G: Terms and Definitions Term Definition Base module Master node with I/O Expansion module Expansion node that responds to master node Local bus header/plug B&B proprietary RS-485 bus interconnection via 14 pin 2 mm connector Manual Documentation Number: Zlinx485m-1808 www.bb-elec.com www.bb-europe.
