FL-net Remote I/O Station

FL654
Instruction Manual

July, 2004

TOSHIBA CORPORATION
NOTE
1. There are two major versions in the FL -net, Ver.1.0 and Ver.2.0. Between these versions, there is no
compatibility. The FL654 conforms to the Ver.2.0.

2. FL-net is 10Mbps Ethernet based network. Therefore 10Mbps HUB is recommended. If 10M/100M
multi -speed HUB is used, fix the port speed to 10M.

3. FL-net is Ethernet based network and uses UDP/IP protocol. However, to avoid collisions and to keep the
real-time data link performance, dedicated FA Link Protocol on UDP/IP is implemented. Therefore FL -net
network cannot be shared with other normal Ethernet devices.

1
CONTENTS

1. System Configuration ..................................................................................................... 3

1.1 FL-net system ............................................................................................................ 3

1.2 FL-net remote I/O station FL654 ................................................................................ 4
1.3 Unit configuration ....................................................................................................... 6

2. Specifications ................................................................................................................ 8

3. FL654 Hardware ............................................................................................................. 9

4. Set Up Procedure .......................................................................................................... 13

4.1 I/O registration method .............................................................................................. 13

4.2 Current I/O configuration method ............................................................................... 14

5. I/O Mapping ................................................................................................................... 15

5.1 I/O auto configuration ................................................................................................ 15

5.2 Checking and registration of the I/O mapping status ................................................. 16
5.3 I/O mapping example .................................... ............................................................. 18

6. RAS Information ............................................................................................................ 19

2
1. System Configuration

1. System Configuration

1.1 FL-net system

FL-net is an open standard network for industrial controllers, such as PLCs, NCs, Robot controllers, etc.
By using FL -net, high-speed, multi vender network system can be easily established.
FL-net is standardized in JIS B3521, and promoted by Japan Electrical Manufacturers' Association
(JEMA).

FL-net is 10Mbps Ethernet based network. Standard Ethernet cable and network devices (HUB,
repeater, etc) can be used.

Station A Station B Station C

FL-net (Ethernet based network)

Station D Station E Station F Station G

FL-net uses cyclic broadcast with common memory system.

A token rounds each station. Each station has FL-net common memory (8.5K words) in it.
When one station get token, this station send its Talker block data to all other stations, then transfers the
token to the next station. In the stations other than Talker station, the received data is stored in its
common memory. As the result, when token rounds all stations, every station's common memory
contents are refreshed as the same each other.

FL-net Common Memory

Station A Station B Station C Station D Station E Station F Station G

A's data A's data A's data A's data A's data A's data A's data
B's data B's data B's data B's data B's data B's data B's data
C's data C's data C's data C's data C's data C's data C's data
D's data D's data D's data D's data D's data D's data D's data
E's data E's data E's data E's data E's data E's data E's data
F's data F's data F's data F's data F's data F's data F's data
G's data G's data G's data G's data G's data G's data G's data

FL-net Token (round robin)

For more information about FL -net, refer to the separate manual.

3
1. System Configuration

1.2 FL-net remote I/O station FL654

The FL654 is a FL-net Ver.2.0 compatible remote I/O station. The FL654 functions as a station of
FL-net.

FL654 External Feature

FL-net FL-net
Station Station

FL-net

P F I I I O O P F I I I O O
L N N N U U L N N N U U
S 6 T T S 6 T T
5 5
4 4

FL-net Remote I/O FL-net Remote I/O

IN: Input module

OUT: Output module
PS: Power supply module

4
1. System Configuration

The FL654 reads data from the input modules cyclically and send it to other FL -net stations (Talker data),
and reads FL-net common memory (Listener data) and writes into the output modules.

FL654
FL-net common memory I/O modules

Input module
Input module
Talker block
Output module
FL-net
Input module
Listener block Ou tput module
Output module

For the memory mapping between the FL-net common memory and the each I/O module, the FL654
has the parameters "Talker stating address" and "Listener starting address".
In the FL-net common memory, the input modules are mapped on the address starting with the "Talker
stating a ddress" in series. And the output modules are mapped on the address starting with the
"Listener starting address" in series.
These parameters are set by hardware switch (rotary switches) on the FL654.

Note:
Other than the input module data, the FL654 sends I/O module status data (4 words) using the
beginning of the Talker block. Therefore, the FL654's Talker block size is the total input module occupied
data size plus 4 words.

For details of the I/O mapping, refer to section 5.

5
1. System Configuration

1.3 Unit configuration

The following figure shows the maximum configuration of the FL-net remote I/O station (FL654 station).
The FL654 station can contain up to 32 I/O modules.

FL-net

Power
supply FL654

Expansion
interface

I/O modules
Pow er
supply Vacant slot (in case of BU668 only)

Expansion
interface

I/O modules
Power
supply Vacant slot (in case of BU668 only)

Expansion
interface

I/O modules
Power
supply Vacant slot (in case of BU668 only)

Expansion
interface

I/O modules

Base:
BU668 8 I/O slot + 1 FL654 slot
BU666 6 I/O slot (5 I/Os at FL654 unit)
BU664 4 I/O slot (3 I/Os at FL654 unit)

Power supply module:

PS693 100 to 240Vac
PS632 24Vdc

Expansion interface module:

IF661 for main and expansion I/O units

6
1. System Configuration

Expansion cable:
CS6R3 0.3m length
CS6R5 0.5m length
CS6R7 0.7m length
CS6*1 1.2m length

FL-net remote I/O station:

FL654 FL-net remote I/O station

I/O modules:
Occupied data
Type Description Talker/Listener
(words)
DI632D 8 points isolated, 12-24Vdc/ac i nput Talker 1
DI633 16 points, 12 -24Vdc/ac input Talker 1
DI634 32 points, 24Vdc input Talker 2
DI635 64 points, 24Vdc input Talker 4
DI635H 64 points, 24Vdc input (high-speed) Talker 4
DI653 16 points, 110Vdc input Talker 1
IN653 16 points, 100-120Vac input Talker 1
IN663 16 points, 200-240Vac input Talker 1
DO633 16 points, 5-24Vdc output Listener 1
DO633P 16 points, 12 -24Vdc output (source) Listener 1
DO634 32 points, 5-24Vdc output Listener 2
DO635 64 points, 5-24Vdc output Listener 4
AC663 12 points, 100-240Vac output Listener 1
RO662S 8 points isolated, relay contact output Listener 1
RO663 16 points, relay contact output Listener 1
AD624L 4 channel, analog input 1-5V/4-20mA, 8 -bit Talker 4
AD634L 4 channel, analog input 0-10V, 8-bit Talker 4
AD624 4 channel, analog input 1-5V/4-20mA, 12-bit Talker 4
AD674 4 channel, analog input ±10V, 12-bit Talker 4
AD628S 8 channel isolated, analog input 0-5V/0-20mA, Talker 8
12-bit
AD638S 8 channel isolated, analog input ±10V, 12-bit Talker 8
DA622L 2 channel, analog output 1 -5V/4 -20mA, 8-bit Listener 2
DA622 2 channel, analog output 1 -5V/4 -20mA, 12-bit Listener 2
DA672 2 channel, analog output ± 10V, 12-bit Listener 2

7
2. Specifications

2. Specifications

The table below shows the FL654 specifications.

Item Specifications Remarks

Standard FA Control Network (FL-net) JIS B3521
Protocol version 2.00
Communication

Bit rate 10Mbps

Electrical IEC68802.3 (CSMA/CD)
interface
Communication FA Link protocol (Ver.2.00)
protocol UDP/IP
Number of Max. 254 stations
stations
Connector 10BASE-T
I/O module Integrated Controller V-series See Note 1 below
I/O processing

model 2000 I/O modules (G2I/O) for applicable I/Os

Number of I/O Max. 32 modules
modules
I/O update Max. 25ms (at 32 I/Os mounted)
I/O mapping Auto detection Tool configuration
Mapping to area 1 or area 2 (selectable) (Future)
Cyclic Size: 8K bit (area 1) + 8K word (area 2) Note 2
Service

transmission Performance: 50ms or less (32 nodes)

Message FL-net message transmission
transmission
External size model 2000 1 slot size
Consumed current 5Vdc, 2.0A or less
Weight Approx. 500g

Note 1: Applicable I/O modules

Module type
Digital input DI632D, DI633, DI634, DI635, DI635H, DI653, IN653, IN663
Digital output DO633, DO633P, DO634, DO635, AC663, RO662S, RO663
Analog input AD624L, AD634L, AD624, AD674, AD628S, AD638S
Analog output D A622L, DA622, DA672

Note 2: Data link performance

Above data is the target specification at the FL-net development. To achieve this specification, each
FL-net node must release Token within 1.5ms. The FL654 satisfies this requirement.
Actual transmission cycle depends on the connected FL-net nodes.

8
3. FL654 Hardware

3. FL654 Hardware

The figure below shows the FL654 external features.

Status display LEDs

RUN/HALT switch

Node address setting switch

( N A-H, NA-L)

10BASE-T connector
(LINE)

Tool port (TOOL)

1 8 TBH TBL LBH LBL

Mode setting switches

Talker starting block Listener starting block

9
3. FL654 Hardware

Status Display LEDs

RUN LNK

LNT PER

I/O

Normal
LED Display contents Details
state
Possible cause at Off:
FL654 hardware status • Power is not supplied
RUN
On: Normal • Node address is "00" or "FF" On
(green)
Off: Error • Node address is duplicated
• Hardware error or WDT
Possible cause at Off:
FL-net in-ring status
LNK • Transmission parameter abnormal
On: Normal (in ring) On
(green) • Network line problem
Off: Out of ring
• Standby request is issued
10BASE-T link test status Possible cause at Off:
LNT
On: Normal • HUB is not normal On
(green)
Off: Error • 10BASE-T cable problem
Parameter setting status Possible cause at On (error):
PER
(red) On: Error • Parameter is not normal Off
Off: Normal • Talker block duplicated
I/O access status Possible cause at Off:
I/O On: I/O access normal • FL654 is not connected to FL-net On
(green) Off: I/O access stop
• RUN/HALT switch is HALT
Blink: Listener is not updated
TX
On: Transmitting Frame is sending from this node On
(green)
RX
On: Receiving Frame is receiving from other node On
(green)

RUN/HALT Switch
This switch is used to stop the I/O processing. Set HALT side at the I/O registration.
Normal position is RUN.

Node Address Setting Switc h

Two hexadecimal rotary switches are provided. These switches are used to set the FL654's FL-net node
address. Setting range is H01 to HFE (1 to 254). NA-H is for upper 4 -bit, and NA-L is for lower 4 -bit.
In the FL-net system, the node address (IP address) 192.168.250.N is used. This switch designates N.
This switch setting status is confirmed at power on initialization. Therefore when the node address is
changed, cycle power off and on. (Factory setting is 01)

10BASE-T Connector (LINE)

Used to connect FL-net transmission line. Use category 5 UTP cable compatible with 10BASE-T.

10
3. FL654 Hardware

Tool port (TOOL)

This is an RS232C serial port used to connect personal computer. This port is used to confirm the I/O
configuration information and to register this information into the FL654's built-in non-volatile memory.
Refer to section 5 for operation details.

The pin arrangement is as follows. The V-series Engineering Tool cable can be used.

Pin No. Signal name Description

1 CD No use
2 RXD Receiving data
3 TXD Transmitting data
4 DTR No use
5 SG Signal ground
6 DSR No use
7 RTS Request to send
8 CTS Clear to send
9 CI No use

Mode Setting Switches

8-pin DIP switches are provided to set the FL654's operation mode. This setting status is confirmed at
power on initialization.

SW No. Setting contents

1 and 2 Ethernet setting

1 2 Setting
On On Future reserve (Down mode)
Off On 100Mbps Half Duplex
On Off 10Mbps Half Duplex
Off Off Auto negotiation
3 and 4 I/O operation setting
3 4 Setting
On On Registered I/O operation mode
Off On Current I/O operation mode
On Off Tool setting mode (future reserve, Down)
Off Off I/O confirmation mode (for I/O registration)
5 Specify the Output module status in the event of FL -net error or FL654 HALT or Down
On: Hold Off: Clear
6 Talker block select
On: Area 1 Off: Area 2
7 Listener block select
On: Area 1 Off: Area 2
8 No use (fix to OFF)

Factory setting is all OFF.

11
3. FL654 Hardware

Talker Starting Block / Listener Starting Block Setting Switches

These switches are used for the memory mapping between I/O modules and FL -net common memory.
Two hexadecimal rotary switches are provided for each Taker and Listener setting .
These switches specify the stating block number in the FL-net common memory for Talker and Listener
respectively. The setting range is H00 to HFF (0 to 255).

TBH: Talker starting block (upper)

TBL: Ditto (lower)
LBH: Listener starting block (upper)
LBL: Ditto (lower)

The correspondence between FL-net common memory address and the block number is as follows.

Area 1 ... 1 block = 2 words (512 word / 256 = 2 word)

Area 2 ... 1 block = 32 words (8192 word / 256 = 32 word)

Area Common memory Block number

address
0-1 0
2-3 1
Area 1 4-5 2
(Bit access) : :
508 - 509 254
510 - 511 255
0 - 31 0
32 - 63 1
Area 2 64 - 95 2
(Word access) : :
8128 - 8159 254
8160 - 8191 255

Area 1: [Common memory address] = [Block number] * 2

Area 2: [Common memory address] = [Block number] * 32

12
4. Set Up Procedure

4. Set Up Procedure

This section explains the general flow of the FL654 setting up.

There is two basic operation methods in the FL654's I/O mapping.

(1) I/O registration method
FL654 operates based on the I/O con figuration information registered in the FL654's non-volatile
memory.
(2) Current I/O configuration method
FL654 reads the current I/O configuration at power up and operates based on this information

Above (2) is easy and no I/O registration is required. However, if some I/O module is failed and no
response at power up, the FL654 cannot recognize the error. As the result, the I/O mapping will be
shifted unexpectedly.
Therefore, above (1) is recommended for normal operation. Above (2) is prepared for test purpose.

4.1 I/O registration method

Initial setting or
configuration change

• Node address
• Talker starting block (Area 1 or 2)
Decide the FL-net • Listener starting block (Area 1 or 2)
parameters • 10M/100M select (Auto negotiation normally)
Refer to section 3

Select I/O confirmation • I/O confirmation mode (DIP-SW 3=Off, 4=Off)

mode • RUN/HALT switch = HALT
Refer to section 3

Mount FL654 and I/O

modules on the unit

Connect PC and run • Connect PC's COM port and FL654's Tool port
HyperTerminal • Run HyperTerminal
Refer to section 5

Turn on power to the • Confirm the I/O mapping by using HyperTerminal

FL654 station • Register the I/O mapping
Refer to section 5

• Registered I/O mode (DIP-SW 3=On, 4=On)

Turn off power and • RUN/HALT switch = RUN
change the switch to • Select output status at error (DIP-SW 5)
normal state
Refer to section 3

13
4. Set Up Procedure

Normal operation A

Connect FL-net
communication cable

Turn on power to the

network devices and to When FL -net network is established, the FL654
remote I/O operation is started.
the FL654 station

4.2 Current I/O configuration method

Operation start

• Node address
• Talker starting block (Area 1 or 2)
Decide the FL-net • Listener starting block (Area 1 or 2)
parameters • 10M/100M select (Auto negotiation normally)
Refer to section 3

Select Current I/O • Current I/O operation mode (DIP -SW 3=Off, 4=On)
operation mode • RUN/HALT switch = RUN
• Select output status at error (DIP-SW 5)
Refer to section 3

Mount FL654 and I/O

modules on the unit

Connect FL-net
communication cable

Turn on power to the

network devices and to When FL -net network is established, the FL654
remote I/O operation is started.
the FL654 station

14
5. I/O Mapping

5. I/O Mapping

5.1 I/O auto configuration

The FL654 reads the mounting I/O status and made mapping between I/O data and FL-net common
memory at power on initialization automatically.
The FL654 has one Talker block and one Listener block on the FL-net common memory.

Input modules are mapped on a Talker block.

• Area 1 or 2 ... Depend on the DIP-SW 6
• Starting address ... Depend on the "Talker starting block" setting (TBH and TBL)
• Size ... Total input modules occupied data size plus I/O status (4 words)

Output modules are mapped on a Listener block.

• Area 1 or 2 ... Depend on the DIP-SW 7
• Starting address ... Depend on the "Listener starting block" setting (LBH and LBL)
• Size ... Total output modules occupied data size

The I/O status information has the following contents.

Address 15 0
Talker start Healthy counter (H0000 to H0FFF)
+1 word I/O module status 1
+2 word I/O module status 2
+3 word Reserve

Healthy counter:
When FL654 is executing the I/O processing normally, this counter is incremented. If it reaches H0FFF,
it returns to 0 and repeats.

I/O module status:

Represents the each I/O module status. Each bit in this word shows the corresponding I/O module
status. The following bit position shows [Unit number]-[Slot number].
0: I/O module error
1: I/O module normal

bit 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0
Status 1 1-8 1-7 1-6 1-5 1-4 1-3 1-2 1-1 0-8 0-7 0-6 0-5 0-4 0-3 0-2 0-1
Status 2 3-8 3-7 3-6 3-5 3-4 3-3 3-2 3-1 2-8 2-7 2-6 2-5 2-4 2-3 2-2 2-1

15
5. I/O Mapping

5.2 Checking and registration of the I/O mapping status

In the current I/O operation mode (refer to section 3), the FL654 starts the operation based on the
current I/O configuration and I/O mapping.

On the other hand, in the registered I/O operation mode (refer to section 3), the FL654 checks the
current I/O configuration and the registered information. When it is correct, the operation is started. But
if it is not correct, the FL654 moves into Down mode to prevent erroneous operation.

For I/O registration, the I/O confirmation mode (refer to section 3) is pro vided.
In the I/O confirmation mode, the I/O configuration and mapping status can be confirmed and registered
by using serial communication terminal such as Windows HyperTerminal.
Refer to section 4.1 for operation procedure.

HyperTerminal setting:

Item Setting
Connection COMn direct
Bit rate 19200bps
Data bit 8 bit
Parity Non
Stop bit 1 bit
Flow control Hardware or Non
Transmit carriage return code CR
Receive carriage return code CR
Local echo On

When HyperTerminal is started and the FL654's I/O confirmation mode is executed, the I/O configuration
and mapping status is displayed on the HyperTerminal screen as shown on the next page.

Confirm the displayed information, and if it is OK, press [Y] then [Enter] keys to save.
When saving is completed normally, the message "saved OK!" is displayed.

16
5. I/O Mapping

****************************************
Talker area head address: 0036W
Listener area head address: 0000W
****************************************
UNIT[0]
SLOT(0): X 1W Talk 0036W
SLOT(1): Y 1W Listen 0000W
SLOT(2): X 1W Talk 0037W
SLOT(3): Y 1W Listen 0001W
SLOT(4): X 1W Talk 0038W
SLOT(5): Y 1W Listen 0002W
SLOT(6): X 1W Talk 0039W
SLOT(7): Y 1W Listen 0003W
UNIT[1]
SLOT(0): X 1W Talk 0040W
SLOT(1): Y 1W Listen 0004W
SLOT(2): X 1W Talk 0041W
SLOT(3): Y 1W Listen 0005W
SLOT(4): X 1W Talk 0042W
SLOT(5): Y 1W Listen 0006W
SLOT(6): X 1W Talk 0043W
SLOT(7): Y 1W Listen 0007W
UNIT[2]
SLOT(0): X 1W Talk 0044W
SLOT(1): Y 1W Listen 0008W
SLOT(2): X 1W Talk 0045W
SLOT(3): Y 1W Listen 0009W
SLOT(4): X 2W Talk 0046W
SLOT(5): Y 2W Listen 0010W
SLOT(6): X 4W Talk 0048W
SLOT(7): Y 4W Listen 0012W
UNIT[3]
SLOT (0): X 8W Talk 0052W

Is this I/O-CONFIGURATION saved?

[Yes or No] ? y

saved OK!

17
5. I/O Mapping

5.3 I/O mapping example

Following figure shows the example of I/O mapping to the FL-net common memory.

In this example, the setting is as follows.

• Talker area = Area 2 (DIP-SW 6 = Off)
• Listener area = Area 2 (DIP-SW 7 = Off)
• Talker starting block = H04 (TBH = 0, TBL = 4) → Talker starting address = H80 (128)
• Listener starting block = H10 (LBH = 1, LBL = 0) → Listener starting address = H200 (512)

[ Unit configuration ]
0 1 2 3 4 5 6 7
I PS F D D D D D D D D
F L I I I I O O O O Unit 0
6 6 6 6 6 6 6 6 6
5 3 3 3 3 3 3 3 3
4 3 3 3 3 3 3 3 3

0 1 2 3 4 5 6 7
I PS S A A D D D S S S
F P D D A A A P P P
6 6 6 6 6 Unit 1
2 2 2 2 2
4 4 2 2 2

[ I/O mapping ]

Talker block Listener block

Common memory area 2 Common memory area 2
Address Address
H80 I/O status (4 word) H200 Unit 0 - Slot 4 DO633 (1 word)
H201 Unit 0 - Slot 5 DO633 (1 word)
H202 Unit 0 - Slot 6 DO633 (1 word)
H203 Unit 0 - Slot 7 DO633 (1 word)
H84 Unit 0 - Slot 0 DI633 (1 word) H204 Unit 1 - Slot 2 D A622 (2 word)
H85 Unit 0 - Slot 1 DI633 (1 word)
H86 Unit 0 - Slot 2 DI633 (1 word) H206 Unit 1 - Slot 3 D A622 (2 word)
H87 Unit 0 - Slot 3 DI633 (1 word)
H88 Unit 1 - Slot 0 AD624 (4 word) H208 Unit 1 - Slot 4 D A622 (2 word)

H8C Unit 1 - Slot 1 AD624 (4 word)

18
6. RAS Information

6. RAS Information

I/O module Status

The FL654 informs the I/O module status to other FL -net stations by adding on the Talker block.
Other controller station can confirm the remote I/O status by this information.

The I/O status information has the following contents.

Address 15 0
Talker start Healthy counter (H0000 to H0FFF)
+1 word I/O module status 1
+2 word I/O module status 2
+3 word Reserve

Healthy counter:
When FL654 is executing the I/O processing normally, this counter is incremented. If it reaches H0FFF,
it returns to 0 and repeats.

I/O module status:

Represents the each I/O module status. Each bit in this word shows the corresponding I/O module
status. The following bit position shows [Unit number]-[Slot number].
0: I/O module error
1: I/O module normal

bit 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0
Status 1 1-8 1-7 1-6 1-5 1-4 1-3 1-2 1-1 0-8 0-7 0-6 0-5 0-4 0-3 0-2 0-1
Status 2 3-8 3-7 3-6 3-5 3-4 3-3 3-2 3-1 2-8 2-7 2-6 2-5 2-4 2-3 2-2 2-1

The FL654 behavior at the FL-net communication problem

(1) When the FL654 is dropped out from the FL-net network
If the output clear mode (default setting) is selected, the FL654 shuts off the all output signals.
If the output hold mode is selected, the FL654 stops I/O processing with the output signals
unchanged.

(2) When the FL654's Listener data are not updated

If all the Listener block data are not updated more than 500ms, the FL654 controls the output signal
off or hold, according to the Clear/Hold setting. However if a part of the Listener block data is
continued to update, this function i s not activated.

(3) When the FL654 is Down mode

The FL654 controls the output signal off or hold, according to the Clear/Hold setting.

19
6. RAS Information

FL654 LED status at Down mode

LED Error contents

RUN PER LNK LNT I/O
(1) Format error
Off Blink Off - Off (2) Parameter registration error
(3) FL-net in-ring error
Off Off Off Blink Off (1) Ethernet setting error (DIP -SW 1, 2)
(2) LAN controller error
Off Off Blink Off Off (1) Node address setting error
(2) Node address duplicated
Off Off Blink Blink Off (1) Protocol version mismatch
(1) I/O operation setting error (DIP-SW 3, 4)
(2) I/O configuration error
Off Off Off - Blink (3) I/O information not saved
(4) I/O information error (saved data error)
(5) I/O mapping error
(1) WDT error
(2) Bus stall
(3) SRAM access error
(4) Illegal interrupt
Off Off Off - Off (5) ROM BCC error
(6) RAM check error
(7) Program BCC error
(8) Module type error
(9) HW revision error

20