The 6-way programming connector provides VCC and ground, TTL level serial RX and TX, and I2C SDA and SCL. The serial port is used by Zelio Soft to program the device. Presumably the I2C interface is used by the EEPROM backup modules.
I have successfully programmed this device using the Sparkfun FT232R breakout board set to 5V. I suspect the official programming cable just contains a MAX232 level shifter or similar.
In Zelio Soft’s monitor mode the PLC’s state is polled via the serial port in the programming connector. The protocol used looks like MODBUS ASCII at 115200 bps, 7 data bits, even parity, 1 stop bit (7E1).
Programming Connector Pinout
Viewed looking at the front of the smart relay.
| 1 | Vcc |
| 2 | Ground |
| 3 | Rxd (serial in) |
| 4 | SCL |
| 5 | Txd (serial out) |
| 6 | SDA |
Update
Gustavo has been kind enough to provide pictures of the programming cable. Thanks Gustavo!
It looks like two 211/411op-amps are used to convert between the different signal levels.
Pin out DB9 (F) | Color cable
1 NC
2 Black
3 Green
4 Red
5 White
6-9 NC
 
|
Hello,
Before all, Thanks for the info.
I tried to connect to a Crouzet Millenium3, because I know that the programming cable is the same like Zelio.
I used a RS232 to TTL converter and connect the pins like you.
Power supply is in pin 1 and 2, and 3 and 5 are the comunications ones.
I set the com port in 115200 7E1, but still no works.
I buyed 2 FT232, but this part will be at home in 20 or 30 days.
Could you give me more information about the cable?
Thanks a lots,
Diego Luca
Hello,
I tried to connect to a Crouzet Millenium3.
I used a RS232 to TTL converter, but I can´t read or write in it.
I know that Millenium3 and Zelio2 are similar, and the same programming cable can be used in both.
Can you give me more information about your cable, and the connection that you made?
Thanks very much,
Hi Diego,
I’m not sure what more information I can give. Have you tried checking that your RS232 to TTL converter is operating at the correct voltages? You could connect RX to TX and do a loopback test to see if your converter is working correctly.
I’ve got the SR3 B261BD interface cable and it has a couple op.amp (411) and voltage comparator (211) and 2 diodes s1j typte.I would like to upload pictures….
Hi Gustavo, I would appreciate some pictures of the programming cable. You can email these to spencer@hexperiments.com. I would like to put these on this site with your permission. Thanks!
Hi, i tried it, works great!
Thanks
i have a problem with this issue
the VCC is important or not
because i have serial rs 232 to usb converter and there is only 3 wires connected
tx rx gnd
VCC is not required. Three wires are sufficient: Rx, Tx and GND.
Be sure that the signals are at 5 V as normal RS-232 levels may damage the PLC.
I believe the ICs labelled 211/411 are Avago HCPL-0211 (logic out) optocouplers.
http://www.avagotech.com/docs/AV02-0674EN
The SR2 USB01 cable also uses two of these, and surprisingly a ST7 8-Bit microcontroller. If I can substitute this with FT232RL I will be very happy.
Thanks for the link. I have had success with a FT232RL connected directly (no optocouplers).
Hi Spencer,
Thanks for this informative site.
I have a Zelio SR2 B201BD that I wish to program from within Zelio Soft 4.5 via USB.
I’m using a “cheap” FT232R -> 5volt TTL device from ebay.
TxD on FT232R -> pin 5 ( TxD ),
RxD on FT232R -> pin 3 ( RxD ),
GND on FT232R -> pin 2 ( GND ).
The FT232R drivers installs automatically in Win7 and shows up in device manager as USB device : “USB Seriel Converter” and as COM device : USB Seriel Port ( COM8)
The COM8 is then manually configured to 115200 baud, 7E1. Flowcontrol is set to “None”.
In Zelio Soft 4.5 the COM8 port shows as an option.
( USB connection is of cause not shown. )
Before connecting to the SR2 I tried to short the TxD & RxD on the FT232R and press the “Test” button.
I then get a “Connection Successfull” 🙂
When connected to the SR2 my setup returns an error ( device not found ). 🙁
I suspect that TxD on the FT232R should in fact go to RxD ( pin 3 ) on the SR2 instead and visa versa, but I’m afraid to kill the module if I’m wrong. :/
Best regards
Niels
i am looking at connection two zelio’s by making a cross over , should just need rx, tx and gnd . then use the serial link function block to transfer data between them . Have you tried this ?
I haven’t tried this. I had a look at the help file, and the SLIn and SLOut blocks both require something external to send a message to the Zelio device. The Zelio will not send data out the serial port by itself.
I would try putting a microcontroller in between the two Zelio devices, and have it query one device then push the result to the other.
Another option is to connect a standard digital output on one to an input on the other and vice versa. You could then signal one device from the other by counting pulses. It depends on what sort of data you need to share between the devices. What are you trying to do?
I am thinking I could double to I-O on a cheap sr2 by using a second module
Hi,
I have succesfully hacked SR2A201BD. I have connected ISP (or JTAG, not sure now) programmer using test pins, backed up all FLASH and put there my bootloader. Now I program this PLC in C language over usart. Zelio is really powerfull without buid-in firmware 🙂
PS: when I have tried to put it to it’s original state from backup, everything works like from box.
PPS: user program of original firmware is saved in EEPROM (I did play with erase eeprom and then write eeprom from backup)
I guess this means that they did not use code protection on the AVR micro?
Thats nice 🙂 id like to do the same. Can you tell me where the isp pins are located?
Hi
Searching for an easy way to connect my zelio to PC found your site.
Would such cable to the job?
http://www.ebay.com/itm/USB-To-RS232-TTL-UART-PL2303HX-Auto-Converter-USB-to-COM-Cable-Adapter-Module-/310676792112
I am asking because I have it already at home.
What driver did you use to connect your board to zelio?
I think that cable should work. Just standard com port drivers for the USB to serial converter will work.
Interesting writeup and thanks for the info! I managed to program an SR2 with just a PL2303 based USB serial converter set to 5V TTL levels, the optoisolators on the ‘official’ cable look to be a low cost way of providing isolation and level conversion at the same time (neat!). The Zelio software supports selecting arbitrary COM port numbers, it’s pretty much plug’n’play, only need to connect RX->TX, TX->RX and GND->GND.
HELLO, I tried this successfully, but after a few seconds communication is lost, how could I fix that?
I used a DIY lead too for the SR2. I used a MAX232 from the PC com1 to the SR2 header, works straight away. If you’re using a laptop with no ground connection charger-type PSU, I recommend using the laptop on battery, or disconnect the laptop mains adapter while you plug into the SR2, just to eliminate any damage the SR2 from any AC mains filter currents that might flow between the devices…..no opto isolation on a max232!
Good point about the isolation. I have only been doing this on the bench, not to a unit that is connected to anything.
Does anyone happen to know what the PIN spacing is on the Programming Cable end?
They are standard 0.1 inch spaced headers in a 2 x 6 layout.
TY
And to be clear, the Programming Connector Pinout, are you showing up a front view of the connection CABLE or connection PORT on Zelio?
I show a view looking down on the connector port in the smart relay.
Hallo, I have a smart relay Zelio total dead sr2b121jd
What influences that can be not alive when whipped or in settings.
Thank you for the information.
Hello i tried it, works great!
Med vänlig hälsning Martin
Hi Spencer, Please i have Zelio Smart Relay SR3 B261BD, and I DON’T the communication cable to upload program onto the device. please which other cable do you recommend i use.
You can use any TTL levl serial cable or breakout board. I use the Sparkfun FT232RL board.
If you are using a homemade cable I recommend you disconnect the smart relay from any mains supply.