MOXA TCC-100/100I User’s Guide

Sixth Edition, September 2006

www.moxa.com/product

MOXA Technologies Co., Ltd.

Tel: +886-2-8919-1230
Fax: +886-2-8919-1231
Web: www.moxa.com

MOXA Technical Support

Worldwide: [email protected]
The Americas: [email protected]

P/N: 1802001000300
 MOXA TCC-100/100I User’s Guide
Any software described in this manual is furnished under a license agreement and
may be used only in accordance with the terms of that agreement.

Copyright Notice

Copyright © 2006 MOXA Technologies Co., Ltd.

All rights reserved.
Reproduction without permission is prohibited.

Trademarks

MOXA is a registered trademark of The MOXA Group.

All other trademarks or registered marks in this manual belong to their respective
manufacturers.

Disclaimer

Information in this document is subject to change without notice and does not
represent a commitment on the part of MOXA.

MOXA provides this document “as is,” without warranty of any kind, either
expressed or implied, including, but not limited to, its particular purpose. MOXA
reserves the right to make improvements and/or changes to this manual, or to the
products and/or the programs described in this manual, at any time.

Information provided in this manual is intended to be accurate and reliable.

However, MOXA assumes no responsibility for its use, or for any infringements
on the rights of third parties that may result from its use.

This product might include unintentional technical or typographical errors.

Changes are periodically made to the information herein to correct such errors,
and these changes are incorporated into new editions of the publication.
 Table of Contents

Chapter 1 Introduction...........................................1-1
Overview .............................................................. 1-2
Product Features ................................................... 1-4
Package Checklist................................................. 1-4
Product Specifications .......................................... 1-4
Schematic ............................................................. 1-6
LED Indicators ..................................................... 1-6

Chapter 2 Installation.............................................2-1
Hardware Installation ........................................... 2-2
Termination Resistor Diagram.............................. 2-7
Function Diagram................................................. 2-7
Isolation Block Diagram....................................... 2-8
Typical Applications ............................................. 2-8

Appendix A Service Information ............................. A-1

MOXA Internet Services ......................................A-2
Problem Report Form ...........................................A-3
Product Return Procedure.....................................A-4
 1
C h a p t e r 1 Introduction

The TCC-100 and TCC-100I are RS-232 to RS-422/485 media converters. The
TCC-100I provides 2 KV of optical isolation.
The following topics are covered in this chapter:

‰ Overview
‰ Product Features
‰ Package Checklist
‰ Product Specifications
‰ Schematic
‰ LED Indicators
MOXA TCC-100/100I User’s Guide

Overview
Introduction
Many of the important devices used as part of today’s industrial applications are
RS-232 devices. This is because RS-232 hardware is relatively easy to design,
and RS-232 devices can be readily connected to most PCs. The drawback is that
RS-232 is a point-to-point interface, and it imposes a distance limitation of only
15 meters between the device and the computer.

To overcome these limitations, many users employ RS-232 to RS-422/485

converters that allow RS-232 devices to connect to an industrial RS-422 or
RS-485 network and transmit data over distances up to 1.2 km. The RS-422/485
standards overcome the distance limitation by using a differential signal for
transmitting data and control signals. Transmission distance and multi-drop
connections are not the only issues of importance for industrial applications In
addition, housing, wiring, power supply, and over-surge protection are also
important issues.
The TCC-100I provides isolation protection for users who need an industrial
grade interface conversion product to extend RS-232 transmission distance and
increase networking capability. The superior industrial design, which includes
DIN-Rail mounting, terminal block wiring, external terminal block power, and
optical isolation for system protection, makes the TCC-100I suitable for use in
critical industrial environments. Simply put, your RS-232 devices can be used as
part of an industrial RS-422/485 network, but without any hardware or software
changes.

1-2
 Introduction

RTS/CTS RS-422 Handshaking Signals

The TCC-100/100I provides RS-422 handshaking signal support. The RTS and
CTS signals help solve the RS-422 signal handshaking problem and reduce data
transmission errors.

Built-in RS-485 ADDC™ Intelligence

ADDC™ (Automatic Data Direction Control), a MOXA leading technology, uses
a clever hardware solution to manage RS-485’s data flow control problem.
ADDC™ is a hardware data flow solution that automatically senses and controls
data direction, making the handshaking signal method obsolete.

Isolation
MOXA’s electrical isolation technology uses two photo couplers to create a gap
in each electrical signal. One photo coupler transforms the electrical signal into an
optical signal, which is transmitted across a small gap, and then the other photo
coupler transforms the optical signal back into an electrical signal. In this way,
the two electrical circuits are completely isolated from each other, limiting the
damage that could otherwise be caused by power surges in the electrical signal.

Reverse Power Protection

The Reverse Power Protection feature provides extra protection against
accidentally connecting the power cables to the wrong terminal. The converter is
designed to detect automatically which power wire is positive and which is
negative, and then adjust the power supply accordingly.

DIP Switch Selectable Terminator

For many products of this type, the termination resistor is set by a jumper located
inside the product’s casing, so that the user must open the casing to disable or
change the resistor’s strength. MOXA offers a better solution. The
TCC-100/100I’s terminator is set with a DIP Switch located on the outside of the
converter’s casing.

Auto Baudrate Detection

The TCC-100/100I incorporates a method for automatically detecting the serial
signal’s baudrate by hardware. This is an extremely convenient feature for the
user. Even if a device’s baudrate changes, the signal will still be transmitted
through the RS-232 to RS-422/488 converter without any problem.

1-3
MOXA TCC-100/100I User’s Guide

Product Features
• RS-232 to RS-422 conversion with RTC/CTS support
• RS-232 to 2/4-wire RS-485 conversion
• Detachable wall and DIN-Rail mounting attachments for easy RS-422/485
wiring
• PWR, Tx, and Rx LEDs
• 16 KV ESD Surge Protection
• 2 KV Isolation (TCC-100I) for both power and RS-422/485 signals
• Operating temperature from -20 to 60°C

Package Checklist
Before installing the MOXA TCC-100/100I, verify that the package contains the
following items:
• TCC-100 or TCC-100I
• User’s Manual (this document)
• Warranty Booklet
Please notify your sales representative if any of the above items is missing or
damaged.

Product Specifications
Model Names TCC-100, TCC-100I
Communication
RS-232 Signal Female DB9 connector
(Supports Tx, Rx, DTR, DSR, RTS, CTS, DCD)
RS-422/485 Signal Terminal block connector (DIP Switch selectable)
4-wire RS-422 (with RTS/CTS): up to 10 nodes (1.2 km)
4-wire RS-485: up to 32 nodes (1.2 km)
2-wire RS-485: up to 32 nodes (1.2 km)
RS-485 Data ADDC™
Direction Control
Baudrate 50 bps to 921.6 Kbps
Surge Protection 16 KV ESD RMS, for all signals
Isolation 2 KV (TCC-100I) for both power and signal
Environment
Operating Temp. -20 to 60°C (-4 to 140°F)
Storage Temp. -20 to 85°C (-4 to 185°F)

1-4
 Introduction

Humidity 5 to 95%RH
Power
Input Power Voltage External Power 12 to 48 VDC, Terminal Block
Reverse Power Protects against V+/V- reversal
Protection
Over Current Protects against 2 signals shorted together
Protection
Power Consumption 400 mA (max.) at 12V
Mechanical
Dimensions 67 × 100 × 22 mm (without DIN-Rail mounting kit)
(W × D × H) 90 × 100 × 22 mm (with DIN-Rail mounting kit)
Case Aluminum
Plug-In Screw #22 – #16 AWG
Terminal Block
Weight 148±5 g

Regulatory Approvals
CE, FCC (Class B)

WARNING 1. This unit is not meant to be sold to consumers. It will only

be shipped to manufacturers or factories.
2. The DC source should come from an external adapter or
12 to 48 VDC source (not from DC mains) by using a
transfer device.
3. This unit should be installed or set up by a qualified
service person.

1-5
MOXA TCC-100/100I User’s Guide

Schematic
11.5 mm 22 mm
67 mm

28.7 mm

100.4 mm
O7
43 mm

O3.5

O4
28.7 mm

LED Indicators
TCC-100/100I’s top panel contains three LED
indicators, as described in the following table:
LED Name LED Function RED PWR
PWR Red indicates the power is on.
GREEN
Green indicates the
TCC-100/100I is receiving data
from the RS-232 port. YELLOW

Yellow indicates the

TCC-100/100I is receiving data
from the RS-422/485 port.

1-6
 2
Chapter 2 Installation

In this chapter, we explain how to install the TCC-100/100I, and show function
and block diagrams.
The following topics are covered in this chapter:

‰ Hardware Installation
‰ Termination Resistor Diagram
‰ Function Diagram
‰ Isolation Block Diagram
‰ Typical Applications
MOXA TCC-100/100I User’s Guide

Hardware Installation
Installing the TCC-100/100I involves five straightforward steps:
STEP 1: Set the DIP Switches
STEP 2: Attach the Power Supply
STEP 3: Wire the Terminal Block
STEP 4: Attach the RS-232 Converter
STEP 5: Test the Connection
The details of each of these five steps are described next.

STEP 1: Set the DIP Switches

The DIP Switches on the TCC-100/100I are used to set the signal transmission
mode and enable or disable the termination resistor. You can configure the
TCC-100/100I to use either RS-422 or RS-485 transmission. Your program and
serial port should be set to match the converter’s settings.
SW1—Switch 1 selects RS-422 or RS-485 mode. The default is “On” for RS-422
mode.
SW2—Switch 2 selects 2-wire or 4-wire RS-485 mode. The default is “On” for
4-wire RS-485. Note that if Switch 1 is set to RS-422 mode, then Switch 2
is inactive.
SW3—Switch 3 enables the terminator to 120 Ohms. When enabled, the 120
Ohm resistor prevents signal reflection during RS-485 transmission. The
default is “On” to enable the terminator. If your particular application does
not require using the termination resistor, then simply set Switch 3 to the
off position to disable it.

2-2
 Installation

Dip Switch Settings

RS-422, SW1 SW2 SW3

Terminator active
ON ON ON 1 2 3

SW1 SW2 SW3

RS-422
ON ON OFF 1 2 3

4-wire RS-485, SW1 SW2 SW3

Terminator active
OFF ON ON 1 2 3

SW1 SW2 SW3

4-wire RS-485
OFF ON OFF 1 2 3

2-wire RS-485 with SW1 SW2 SW3

Terminator
OFF OFF ON 1 2 3

SW1 SW2 SW3

2-wire RS-485
OFF OFF OFF
1 2 3

2-3
MOXA TCC-100/100I User’s Guide

The newly implemented DIP-2 Switches are used to configure the pull high/low
resistors for different applications.

Pull High/Low Resistor DIP-2 SW1 DIP-2 SW2

150K (default) OFF OFF
1K ON ON

NOTE We recommend setting the pull high/low resistor to 1K (ON/ON)

when termination is enabled.

2-4
 Installation

STEP 2: Attach the Power Supply

The TCC-100/100I is powered by an
external 12 to 48 VDC power supply.

V+
To connect the power supply, run two

V-
wires from the V+ and V- terminals on
the TCC’s 3-connector terminal block
to the DC power supply, as shown in
the figure. Once the power supply is
- connected to its power source, the
Power Supply PWR LED located on the TCC’s top
+ 12 - 48 VDC
panel will illuminate in red.
NOTE: The TCC-100/100I provides reverse power protection. It will
automatically detect which power wire is negative, and which is positive.
STEP 3: Wire the Terminal Block
There are three wiring options available for connecting to the TCC-100/100I’s
RS-422/485 terminal block.
2-wire RS-485
When using the 2-wire RS-485 wiring option,
Tx+(B) connect three wires from the TCC-100/100I’s
Tx-(A)
Data + Rx+(B)(Data+)
terminal block to the opposite connection. As
Data - Rx-(A)(Data-) shown in the figure, connect from Data+ to
RTS+(B) Data+, from Data- to Data-, and from SGND
RTS-(A)
CTS+(B)
to SGND.
CTS-(A)
SGND SGND

4-wire RS-485
When using the 4-wire RS-485 wiring
Rx+ Tx+(B) option, connect five wires from the
Rx- Tx-(A)
Tx+ Rx+(B)(Data+)
TCC-100/100I’s terminal block to the
Tx- Rx-(A)(Data-) opposite connection. As shown in the figure,
RTS+(B) connect from Tx+(B) to Rx+, from Tx-(A)
RTS-(A)
CTS+(B)
to Rx-, from Rx+(B) to Tx+, from Rx-(A) to
CTS-(A) Tx-, and from SGND to SGND.
SGND SGND

2-5
MOXA TCC-100/100I User’s Guide

RS-422
When using the RS-422 wiring option, first
Rx+ Tx+(B) follow the 4-wire RS-485 wiring instructions
Rx- Tx-(A)
Tx+ Rx+(B)(Data+)
given above.
Tx- Rx-(A)(Data-)
CTS+ RTS+(B) Optional RTS/CTS Handshaking Signals
CTS- RTS-(A) If your software is set up to send and receive
Optional
RTS+ CTS+(B) RTS/CTS signals over separate wires, you
RTS- CTS-(A)
SGND SGND should also connect from RTS+(B) to CTS+,
from RTS-(A) to CTS-, from CTS+(B) to
RTS+, and from CTS-(A) to RTS-.

STEP 4: Attach the RS-232 Female DB9 PIN RS-232

Connector 1 DCD
Depending on your application, 5 4 3 2 1 2 TxD
use the appropriate serial cable to 3 RxD
connect from the TCC-100/100I’s 4 DSR
RS-232 female DB9 port to your 5 GND
RS-232 device, or to your 6 DTR
computer’s COM port. 7 CTS
8 RTS
9 8 7 6 9 ---
RS-232 Pin Assignment Diagram

STEP 5: Test the Connection

After setting the DIP Switches, connecting the power, wiring the terminal block,
and attaching the RS-232 connector, we suggest using a console terminal program,
such as HyperTerminal or MOXA Terminal Emulator, to test the connection. If
you have an RS-422/485 serial board (such as the MOXA CP-132, a 2-port
RS-422/485 board) installed in your PC, you can connect your PC’s COM port to
the TCC-100/100I’s RS-232 port, and then connect the TCC-100/100I’s
RS-422/485 terminal block to one of the RS-422/485 serial board’s ports.
Alternatively, if you have already set up an RS-422 or RS-485 network, you can
also connect the TCC-100/100I’s RS-422/485 terminal block directly to that
network. Next, start HyperTerminal or MOXA Terminal Emulator, and then open
a connection to both the COM port, and the port associated with the
TCC-100/100I’s RS-422/485 port. Simply type a few characters on your PC’s
keyboard. The characters you type should show up in the HyperTerminal window
that is currently inactive, indicating that the typed characters were transmitted
between the TCC-100/100I’s RS-232 port and RS-422/485 terminal block
connector.

2-6
 Installation

Termination Resistor Diagram

Termination is designed to Termination Resistor:
mitigate noise from the S3 On to Enable
S3 Off to Disable
RS-422/485 transmission
signals. If the network cable is R
too long, undesirable
transmission-line effects will RxD+
arise. The best method for
mitigating energy on an unused RxD-
conductor is to dissipate the
energy as heat by terminating both ends of the unused conductor to ground with
resistors (so-called bi-directional termination). The resistance of the resistors
should be equal to the characteristic impedance of the line. The most common
RS-485 twisted pair has a characteristic impendence of 100-120 Ohm. MOXA’s
termination technique is bi-directional termination, which offers excellent signal
integrity. With this technique, the line drivers can be located anywhere on the
network.

Function Diagram
Communication
TxD Controller TxD+

RS-422
RxD
RS-232 RS-422/485 TxD-
RTS

RS-485
Line Driver Line Driver RxD+ (Data +)
CTS
RxD- (Data -)
GND ADDC
Logic

Isolation

2-7
MOXA TCC-100/100I User’s Guide

Isolation Block Diagram

Typical Applications
RS-485 Application
A typical RS-485 application for the TCC-100/100I is depicted in the following
figure. In this scenario, two TCC-100I units are used to connect two PCs to an
RS-485 network. The third TCC-100I is used to connect the PLC—which is
designed for the RS-232 interface—to the RS-485 network. In this way, both of
the PCs are able to interact with the PLC and the LCD Display.

T Tx+(B)

RS-232 Rx

RS-232 Tx

PWR
Tx (A)
Rx+(B)(Data +)
Rx (A)(Data )

RS-232 to RS-422/485

Transioʳ
RTS+(B)

RS- 422/485
RTS (A)

converter

RS -232
CTS+(B)
CTS (A)
SGND

TCC-100
V+
DC9~30V
V

R RS-232
MOXA PC
TCC-100I
RS-485
DC9~30V
V
R Network
TCC-100

V+
RS-232 to RS-422/485

RS- 422/485

SGND
Transioʳ
RS -232

converter

CTS (A)
CTS+(B)
RTS (A)
RTS+(B)
RS-232 Rx
RS-232 Tx

Rx (A)(Data )
Rx+(B)(Data +)
PWR

Tx (A)
Tx+(B)

RS-232 T
MOXA
PC LCD Display
TCC-100I
T Tx+(B)
RS-232 Rx

RS-232 Tx

PWR

Tx (A)
Rx+(B)(Data +)
Rx (A)(Data )
RS-232 to RS-422/485

Transioʳ

RTS+(B)
RS- 422/485

RTS (A)
converter

RS -232

CTS+(B)
CTS (A)
SGND
TCC-100

V+
DC9~30V
V

R RS-232
PLC
MOXA
TCC-100I

2-8
 Installation

RS-422 Application
A typical RS-422 application for the TCC-100/100I is depicted in the following
figure. In this scenario, two TCC-100I units are used to create a point-to-point
connection between a PC and a scales. The advantage of using two TCC-100I
units to convert from RS-232, to RS-422, and then back to RS-232, is that the
RS-422 cable connecting the two converters can be up to 1.2 km in length (this is
quite an improvement compared to the 15-m distance limitation imposed by the
RS-232 interface).

Rx(+/-) Tx(+/-) Tx+(B)

RS-232 Rx

RS-232 Tx

PWR
V
DC9~30V Tx (A)

TCC-100
V+
Rx+(B)(Data +)
Rx (A)(Data )

RS-232 to RS-422/485
RS-232 to RS-422/485

Transioʳ
RTS+(B)

RS- 422/485
SGND

RS- 422/485
Transioʳ
RTS (A)

converter
RS -232

RS -232
converter
CTS (A)
CTS+(B) CTS+(B)
RTS (A) CTS (A)
RTS+(B) SGND

TCC-100
RS-232 Rx
RS-232 Tx
Rx (A)(Data )

w/ optional RTS/CTS
Rx+(B)(Data +)
V+
DC9~30V

PWR
Tx (A)
V
Tx+(B)

RS-232
RS-422 Point-to-Point
MOXA Communication MOXA Scales
PC
TCC-100I TCC-100I

2-9
 A
Appendix A Service Information

In this appendix, we show you how to contact MOXA for information about this
and other products, and how to report problems.
The following topics are covered:

‰ MOXA Internet Services

‰ Problem Report Form
‰ Product Return Procedure
MOXA TCC-100/100I User’s Guide

MOXA Internet Services

Customer satisfaction is our number one concern, and to ensure that customers
receive the full benefit of our products, MOXA Internet Services has been set up
to provide technical support, driver updates, product information, and user’s
manual updates.

The following services are provided

E-mail for technical support: .....................................................support@moxa.com

Website for product information:..................................................... www.moxa.com

A-2
 Service Information

Problem Report Form

MOXA TCC-100/100I

Customer name:
Company:
Tel: Fax:
Email: Date:

MOXA Product: † TCC-100 † TCC-100I

Serial Number: ______________________________________

Problem Description: Please describe the symptoms of the problem as clearly

as possible, including any error messages you see. A clearly written description of
the problem will allow us to reproduce the symptoms, and expedite the repair of
your product.

A-3
MOXA TCC-100/100I User’s Guide

Product Return Procedure

For product repair, exchange, or refund, the customer must:
 Provide evidence of original purchase.
 Obtain a Product Return Agreement (PRA) from the sales representative or
dealer.
 Fill out the Problem Report Form (PRF). Include as much detail as possible
for a shorter product repair time.
 Carefully pack the product in an anti-static package, and send it, pre-paid, to
the dealer. The PRA should be visible on the outside of the package, and
include a description of the problem, along with the return address and
telephone number of a technical contact.

A-4