I/O Controller

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- Features
- Applications
- Download
- Topology
- Specifications
- Device extensions
- Software
- FaQ & Support
- Order
- Products

Two devices can be connected to each other (the Box-2-Box mode), digital signals and RS232 can then go back and forth across the network. The I/O Controller contains: 1x RS-232/485 (Terminal server, virtual serial port) 8x digital input 8x digital output The product can not only be a "TCP Server", but also can act like a "TCP Client/Server". This means, when your digital input value changes, IO Controller connects to the server via TCP/IP and sends a 7-byte information packet about the input change over the M2M (Machine to Machine) protocol. The RS-232/485 serial port can be connected to your PC's virtual serial port using the HW Virtual Serial Port software, the remote digital I/O can be dirrectly controlled from this software. We provide you with the sourcecode of routines written in MS Visual Basic, Delphi, Borland C++, JAVA, PHP and others to facilitate your implementation of the IO Controller into your system.

Big product photos: 1 2 3 4 5

Basic features

• 1x RS-232 or RS-485 serial port accessible over Ethernet or as a COM5 in windows (HW Virtual Serial Port) .
• 8 optocoupled digital inputs
• 8 digital open-colector outputs
• The inputs and outputs are controlled over a M2M (Machine to Machine) protocol. They can be controlled directly from a windows software (see examples), WWW page (PHP / Java) or from the HW VSP software (Virtual Serial Port)
• 2 I/O Controller's can be connected to each other, so they can "tunnel" a serial port + 8x Ethernet input + 8x Ethernet output.
• The device supports TCP Server, TCP Client/Server, UDP modes.
• You can use a 128 bit authorisation encryption (TEA), or limit the access to the device to a predefined IP address range.
• Libraries for MS Visual Basic, Delphi, Borland C++, JAVA, PHP and others..

Typical applications

A typical application is remote access to a RS232 or RS485 controlled technology. I/O controller is an ideal device if you need remote digital I/O signalizations (ethernet input, ethernet output), remote relay control, server accessible remote inputs together wirh a RS-232 or RS-485 bus for a bar code reader, display, etc...

You can access the device using the HW VSP software, or you can write your own software using our wide examples and source codes library.

Applications examples

• Remote control of technology over RS-232 and RS-485 bus
• Remote control of displays and signalling
• Remote reading of PIR sensors, door contacts and security systems
• Remote relay control
• Industrial I/O
• Card readers, RFID readers
• Sales machines
• Security alarms
• Attendance systems
• UPS controll and logging
• Bar code readers

Example applications

Here are some more detailed application exapmles:

• Manufacturing and workers control from an ORACLE server
• A simple attendance system
• Remote RESET of a failure device
• Remote temperature control with the possibility to turn on cooling or heating
• Alarm reporting from a security center
• A simple parking management system

Typical wiring

• Connecting RS-232 and 8 + 8 digital I/O signals over Ethernet
• Controlling RS-232 and remote I/O pins from PC over Ethernet
• Remote I/O pins control from a WWW page or a user interface

Downloads & Datasheets

I/O Controller - Flyer - a brief product flyer (2 page product description) I/O Controller PL - MANUAL - A detailed product manual I/O Controller - A detailed datasheet to older version in metal housing.     Hercules / download - Configuration and setup utility for Windows HW VSP / download - Virtual Serial Port) SW examples for: Delphi, C++, JAVA, PHP and more..

Why should you choose HW group's I/O Controller?

• We can help you solve your application problems - as a manufacturer, we are able to give you the best technical support and fix your problem.

 
• The I/O Controller uses open standards, we can answer any questins regarding the device, all the protocols are well documented.
   
• FREE FW UPGRADE - If you have an older device version, we will upgrade your firmware for free.
   
• Wide range of solved examples, we frequently add more.
• The device can be supplied in a customer modification as a OEM product.
• We also supply a built-in (Embedded) version - see the Charon I product .

System topology

• TCP/IP Server   [Client -> Server]
  The I/O Controller waits as a TCP server until any side (PC or server) opens a TCP connection. When the connection is established, the internal buffered data is sent and then the device allows communication as a standard "terminal server".
  The digital I/O (digital inputs and outputs) can be controlled over a M2M (Machine to Machine) protocol using the extended RFC2217, but only if NVT support is enabled.
  
  
• TCP/IP Client/Server    [Server <- Client]
  The I/O Controller received serial port data into its internal buffer and tries to send them to the server. It will try to open a connection to the preset IP address and port. If the attempt was unsuccessful, it waits for a second in the TCP Server mode and then tries to open the connection again.
  The digital I/O (digital inputs and outputs) can be controlled over a M2M (Machine to Machine) protocol using the extended RFC2217, but only if NVT support is enabled.
  
  
• UDP/IP
  The data is transferred in UDP packets, with no delivery notification. The portbox uses a sophisticated "Packetizer", which allows various conditions of what can and what cannot be send from the serial line to Ethernet.
  The remote ethernet I/O (digital inputs and outputs) cannot be controlled in the UDP mode..
  
   
• VSP (Virtual Serial Port)
  You have a HW VSP software which creates a virtual COM port under Windows OS, so that the device acts like it's connected directly to your PC, though it's a virtual remote port. If the buffer is enabled and the TCP connection is not available, the data is stored into the internal buffer memory.
  The remote ethernet I/O (digital inputs and outputs) can be controlled from the HW VSP software in the "Binary I/O", tab, if the NVT support is enabled.
  

Technical specifications

I/O Controller's inputs
All 8 digital inputs are optocoupled with common ground on IGND pin. You need to connect this pin to the GND pin on your connector. You can also control the pins using contacts which are connecterd to the POWER pin. The maximum power drain is 200 mA!

Built in RS-485 support
The I/O Controller handles the RS-485 line similary to the PortBox - Revision 1 device, details can be found in the datasheet, or in the PortBox description.

Possible device extensions, coming soon...

The following options will either be implemented in the following firmware version, or in the next device version.

• M2M (Machine to Machine) protocol extension: WWW pages and other interfaces (SNMP, WWW, XML, Modbus/TCP) are implemnted in the Damocles device, which we are working on.
• Built-in 4x Ethernet port 10/100 Mbit switch Ideal for applications where you don't have enough free Ethernet ports or cables, or you cannot use a stand-alone switch or hub - customer solution.
  

Questions and comments

If you are interested in any of these modifications, need help implementing them in your projects, or if you want a specific customer solution, feel free to contact us

Built-in I/O Controller version - Charon I module

The I/O Controller box can be replaced with a module version, which looks like a big integrated circuit and can be placed on a printed circuit board of a customer solution.

The Charon I module contains a similar firmware. Digital inputs/outputs are combined in one 8-bit port. You can use setup to control which pins are outputs and which pins are inputs, or you can set all the pins as output or input.

The Charon I has 24 pins and measures approx. 34x42 mm (2x12 pins with 100 mil diameter). You only need to place a supplied transformer and a RJ45 connector outside the module.  

The Charon I module is an ideal solution for you application if it works with PortBox or I/O Controller.

Useful SW

• Hercules SETUP Utility
  When testing the I/O Controller device, the "Test mode" tab in our Hercules SETUP software can be quite useful. In the "test mode", the software highlights the NVT commands, you can send and write the commands in the HEX form.
   
  
    
• HW Virtual Serial Port
  A virtual serial port driver is a software tool which creates an imaginary serial port in the windows system, for example COM5. This data is then redirected to another hardware device.

Examples with sourcecode showing how the I/O Controller can be used

• Borland C++ communication example
  A simple communication example with a TCP/IP device in Borland C++ Builder 6.00. The example demonstrates a simple Client terminal and basic NVT commands (Network Virtual Terminal) = Are You There and I/O functions.
  
• Delphi Charon 1 - NVT communications example
  A simple communication example with a TCP/IP device in Borland Delphi 5 demonstrates a simple Client terminal and basic NVT commands (Network Virtual Terminal) and ethernet I/O functions.
  
• MS Visual Basic example
  Simple routines for NVT commands with a TCP/IP device over Winsock in MS Visual Basic 5.0. Simple commands for remote pins control are implemented, TEA is not.
   
• Java NVT simple Code Example
  A very simple remote I/O pins control in a JAVA application. This application is not password protected, so you can modify it to suit your needs.
   
• PHP I/O Controller example
  A very simple digital I/O pins control. The user requests a WWW page from a PHP server, which opens a connection to a predefined IP address and port and reads the values.
  
  
• LabVIEW driver for the I/O Controller
  The german company MJH Software sells a driver which you can use to control the device from DASYLab and LabVIEW. You can find the details on their website, here is a screenshot from the tested application.
  
  
• Tom Boyd from the http://sheepdogsoftware.co.uk (server for the SW developers and schools) tested IO Controller and updated our original Delphi application.. (sw screenshot: I/O Controller Excerciser / SW download ).
  

NVT (Network Virtual Terminal) protocol description

FAQ & Support

Q: How long does it take to deliver a packet containing the input-change information?
A:  This time cannot be exactly defined over a standard network, because it depends on the network traffic, etc. But the I/O Controller tries to setup the connection and send the data as fast as possible according to the network specifications. Practically it might take 15-25ms to deliver the packet even on high traffic networks. If the system also tries to set the output state, the reaction time will be 20-40ms.

Q: Does the I/O Controller send information to the TCP server about digital input's change or whether there is any data received over the serial port?
A:  Yes, there are two such situations:
a) A TCP connection is established - A digital input's change is signalled with a NVT sequence containing a new value of inputs.
b) A TCP connection is closed - If the device works in the "TCP Client/Server" it will try to establish a TCP connection and send the data in a NVT sequence. If if fails establishing a connection, the inputs change is not buffered or stored.

Q: If I connect 2 I/O Controllers to each other, as described on page 27 in the datasheet, can I read the inputs from a PC?
A:  No, the I/O Controller only supports one TCP/IP connection at a time.

Q: Can we use one I/O Controller device from different PC in one network?
A:  Yes, but not in one time - You can connect from PC1, send the command Read/Write values, device confirm it and you close TCP connection.
It takes around 20ms or deal time, than you can do the same from another computer. This mesna, that there is limit of One TCP Connection in one time only.

Q: How to secure I/O Controller against hackers?
A:  You need to spend some time building up you network's security, the standard is a firewall separated Ethernet network. The device can be setup to respond only to requests from a certain IP range, outside this range it wil not answer even if only pinged. You can also use TEA (Tiny Encription Algorithm) for client authorisation. If you use TEA, the password is not transfered via the network.

Q: What is a packetiser ?
A:  Packetiser is a group of conditions, controlling the RS-232 to Ethernet packets algorithm. In the TCP/IP mode, the packetizer is controlled only with a "Serial line timeout" parameter, which defines a length of space after the last received character before creating and sending a packet.

Q: We want to use our own software to control the device, are there any SW examples or libraries?
A:  Yes, please look at our Support & Download page, where you can download many examples for Borland C++ and Delphi.
We even have very simple examples in Visual Basic, JAVA and PHP.

Q: We need this device to control a 230V device. Do you have a version with such outputs?
A:  Yes, but regarding to different power parameters in different countries and price of the certificationhneeded, we mostly recommend to place the I/O Controller to a DIN molding together with a relay. You can e-mail us, if you have further questions.

Q: How does the RS-232/485 work? Is there a RS-422 version available?
A:  Yes, the I/O Controller is basically an expanded PortBox (RS-232/485 - Ethernet Converter), You can choose between RS-232 / RS-485 using the DIP switches. For the RS-422 and external unit is needed.

Q: The PortBox (RS-232/485 - Ethernet Converter) can be controlled via the virtual COM port for Win 2000 and XP. Can this be used for I/O Controller?
A:  Yes, you can not only control the the RS-232 line from the Virtual COM port, but since version 2.19b also the digital inputs/outputs.

Ordering

The products are on stock and we can send them worldwide with FedEx and other couriers. The price can be found in the pricelist. In the Czech republic, you can also order using our eshop - obchod.HW.cz.

I/O Controller set

• I/O Controller PL [600291] (photo)
• DB9 LapLink cable 2m [600063]
• 1x Power adaptor "wall plug" - [600 080]
  You can change the type of the adaptor to UK or USA version, note this in your order
• I/O Controller Test board [600032]
  8x LED (outputs) and 8x DIP (inputs) on a small PCB - detailed image
• Printed datasheet - "I/O Controller "
• CD with documentation, FirmWare versions, testing utilities and other SW

-> Order 

Ordering versions

The I/O Controller can be supplied in several versions, according to the bellow described ordering number. If you do not specify a device version in your order, we will send you a prefered type. The delivery terms of the non-prefered types should be verified by phone or requested in your order confirmation.

Other accessories

• Power adaptor - USA version - 12V / 0,5A [600 081]
• Power adaptor - UK version (Great Britain) - 12V / 0,5A [600 082]
  
• DIN Rail box set for DIN molding mounting [600 025]
• I/O Controller Test board [600 032]
  A test board for easy setup and debugging of your applications for the I/O Controller. It's connected to 20 pin connector in the delivery.
• DB9 Prolong cable 2m [600 064]
  A prolonging cable Canon 9 – connected 1:1, 2 meters long.
• DB9 LapLink cable 2m [600 063]
  RS-232 LapLink communication cable for PC connection.
  
• I/O Controller 20 pin connector [600 034]
  2x 10-pin connectors for connecting the I/O cables to the I/O Controller [600026]
  
• I/O Controller DB37F Test board [600 033]
  A test board for easy setup and debugging of your applications for the I/O Controller
  
• DIN Relay - 1x switch contact 10 A [600 084]
• DIN Relay - 2x switch contact 10 A [600 085]

Related products

• PortBox
  The RS232/485 - ETHERNET converter with the Server or Client/Server mode, TCP/IP or UDP/IP protocols, remote virtual serial port control over RFC2217 and more..
• PortStore
  512 or 2048 kB buffer memory. The stored data can be accessed over Ethernet (TCP/IP). Typical PortStore application is buffering data from PBX, or remote serial device access.
• IP Relay
  2 Relay contacts + RS-232/485 converter (terminal server) , supports the Server and Client/Server mode, NVT, TEA authorisation, RS-232 "tunneling" over TCP/IP i UDP/IP etc..  
• HW Virtual Serial Port
  Free Virtual Serial Port driver for Windows is a software tool which adds a virtual Comm port to the system, for instance COM5, and all the data from this port is re-directed to another TCP/IP device on the Ethernet network.  
• Charon I module
  Embedded serial line to Ethernet converter module, you can connect measuring devices, SNMP interface, thermometers etc...