Help with Cutler Hammer D100A PLC (Toshiba EX40)

eagle32

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Oct 2009
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Hi every one,i am new to this forum
Here's some problems i need your helps.

I've recently purchased the 2nd hand Cutler D100A plc and Toshiba Ex2040PRGB LCD programer (not version 2) from ebay.

Please help me solve these problems i have with these equipments:

1:what cable do i need to program the Cutler D100A PLC from the Toshiba LCD programer.(I've used the Cat5 patch from my working internet router lead. When i plug in the PLC with the programer: FAULT,LOW BATTERY led came on.So is this sounds ok?

2.Does the Toshiba LCD programer (not verson 2) compatible with the D100A?

3.The there's nothing in the memory cartridge for this PLC(D100)as it said BLANK memory cartridge on the memory slot,so do i need a memory cartridge to do programing?

4.When PLC powered on with LCD programer pluged in , POWER,RUN,FAULT,LOW BATTERY led came on. Is this normal?
When programer unpluged : POWER,RUN led indicated

ps. I've opened the PLC and checked battery status: 2.96VDC, is this ok?


Any comments or solutions from you will much appreciated
Please see pictures from below for my clear explaination

http://img.villagephotos.com/imageview.aspx?i=25814459
http://img.villagephotos.com/imageview.aspx?i=25814460
 
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Hi I use a toshiba PDD software in dos in a virtual PC. I have an ethernet like cable going to a plug in db9 converter. I then talk with the PC. I use to get too frustrated with the programmer. I can try dig out the details at work in about 12 hours if you want.

Pdd is toshiba dos software for EX40/20
The ethernet cable I have is not a std crossover or a patch cable I'll give details later on.
I don't think std cable will work and if I remember it can do silly things with the LED's.
 
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Here's some info that I recall. The cable does use ethernet type connectors, RJ45. The pinout is different than ethernet configuration however. The pinout is as follows:
PLC end----------------LCD Programmer end
pin 1----------------------pin 8
pin 2----------------------pin 7
pin 3----------------------pin 6
pin 4----------------------pin 5
pin 5----------------------pin 4
pin 6----------------------pin 3
pin 7----------------------pin 2
pin 8----------------------pin 1
The cable itself is a flat ribbon style 8-conductor but I think using
Cat5 cable should work.
Even if you cant find actual pin numbers on the connectors, just start with the left side of the connector for one end and the right side for the other end.
Search this site for D100, I and others have some old posts on the subject.

See this link post #12.
http://www.plctalk.net/qanda/showthread.php?t=8157&highlight=d100

The Toshiba lcd programmer should be compatible, Toshiba made the D100 as a private label copy of the EX40.
The memory cartridge was like a floppy disk or USB memory stick. You could read and write the program in the PLC to or from the PLC. The programmer did not store anything. A memory cartridge (EEPROM) was not necessary for it to function, just storage or moving the program to another PLC.
Probably a good idea to NOT unplug the battery unless the PLC is powered up, the program in the memory will be gone fairly quick. When they were new you had enough time to change the battery but the storage capacitor for the onboard plc memory may not be very good.
 
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Some more info.
Link to manual for the EX40:
http://www.toshiba.com/ind/data/tag_files/EX20_40%20Plus%20Manual_506.pdf

See page I 54 in the 506 manual about the battery indicator.

Link to old DOS software:
http://www.toshiba.com/ind/data/tag_files/EXPDD2040-V2 Software_2065.ZIP

D100CPM232 is the C-H part number for the computer interface module.
I can't find the Toshiba part #.

Power and Run are the only two Led's that should be on for normal.
The Batt low and Fault errors most likely are coming from the wrong interface cable you are trying to use.

The battery is not likely your problem since the voltage is nearly 3 volts.
Also, I think I may be wrong about changing the battery with it powered up, the manual says to turn off the power first before changing the battery. It also says you have about 5 minutes to replace the battery.
 
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One more post that might help. Here is a link that I posted on another site if you want to build your own interface. This is a hand-drawn schematic of the interface adapter. A MAX232 IC can be substituted for the LT1081 but the pinouts are different.

****** Please note a minor drawing omission: ******
The " + " side of C4 connects to the dotted line about 1/4 inch away.
The download button for the drawing is at the bottom.
 
Hi I use a toshiba PDD software in dos in a virtual PC. I have an ethernet like cable going to a plug in db9 converter. I then talk with the PC. I use to get too frustrated with the programmer. I can try dig out the details at work in about 12 hours if you want.

Pdd is toshiba dos software for EX40/20
The ethernet cable I have is not a std crossover or a patch cable I'll give details later on.
I don't think std cable will work and if I remember it can do silly things with the LED's.

Hi Rigicon,Thank you

Does the PDD sofware works on windows XP? Im not familair with the 'virtual PC' that you have.
By the way, do you know the pin info for the db9 converter or else i'll just need to get one from the electronic stores.

Are there any socket behind my PC mother board that can plug in with the db9 socket ,do i need to activate this serial port on my PC when the socket pluged in with the PLC ?

If i can get the PLC communicate with my Computer through the software that will be much easier on programing .I get frustrated some times with this programer.Especially i am a left hander. :D

Thanks
 
Here's some info that I recall. The cable does use ethernet type connectors, RJ45. The pinout is different than ethernet configuration however. The pinout is as follows:
PLC end----------------LCD Programmer end
pin 1----------------------pin 8
pin 2----------------------pin 7
pin 3----------------------pin 6
pin 4----------------------pin 5
pin 5----------------------pin 4
pin 6----------------------pin 3
pin 7----------------------pin 2
pin 8----------------------pin 1
The cable itself is a flat ribbon style 8-conductor but I think using
Cat5 cable should work.
Even if you cant find actual pin numbers on the connectors, just start with the left side of the connector for one end and the right side for the other end.
Search this site for D100, I and others have some old posts on the subject.

See this link post #12.
http://www.plctalk.net/qanda/showthread.php?t=8157&highlight=d100

The Toshiba lcd programmer should be compatible, Toshiba made the D100 as a private label copy of the EX40.
The memory cartridge was like a floppy disk or USB memory stick. You could read and write the program in the PLC to or from the PLC. The programmer did not store anything. A memory cartridge (EEPROM) was not necessary for it to function, just storage or moving the program to another PLC.
Probably a good idea to NOT unplug the battery unless the PLC is powered up, the program in the memory will be gone fairly quick. When they were new you had enough time to change the battery but the storage capacitor for the onboard plc memory may not be very good.


Hi jrwb4gbm, Thank you

The PLC communicated with the programer perfectly now after i replaced a new connector with your pin configuration.

If i get an EEPROM cartridge from Toshiba ex ex20 ex40 eprom RM66.Will it compatible on my C H controller?

My PLC part number is D100CRA40A ,Toshiba part number EX40--MARD8 Compatible with EX20 Plus and Ex40 Plus Controller .Based on this website http://xtronics.com/toshiba/cutlerxref.htm
What computer interface module do?

Thanks
 
eagle32 The PDD software is not compatible with winXP too old. It might run in a cmd prompt. I use Virtual PC freely downloadable from microsoft. Just google or Bing Virtual PC in microsoft.
Pdd needs a harware Com port.
The drawing for the flat ribbon cable that jrwb4gbm gave is correct - Thanks. I use the same cable mine is a blue cable part number
PHYCO AWM STYLE 20251 E212689 60ºC 150V VW-1 26AWG
Unfortunately I have no idea where it came from. Then it plugs into an adapter again I can't remember written on the adapter is NEVADA WESTERN SUNNVALE CA - Blue RJ45 one side and a 25pin other side which I have a D9/D25 adapter.Sorry I can't find any more info on the converter here are some pics.
If jrwb4gbm PDD software is not ok then let me know so i can dig another version out. No disrespect jrwb4gbm you got there first.

IMAG0025.jpg IMAG0026.jpg IMAG0027.jpg
 
rigicon
So if i've got a 25 pins db9 male, plug into the pc port, and adapter on the other side is the female socket use to plug in the RJ45 socket coming from my PLC .Then will it works?
Please see the pic below for my pc serial ports.The port in red from PC i have to plug the adapter in, is that right?




Sorry it looks kinda messy here .
 
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Hi jrwb4gbm,

If i use DB9 Female to RJ 45 Female Modular Adapter http://www.cable-trader.co.uk/items/db9-female-to-rj45-female-modular-adapter .Will it works?
OR
Should i use DB25 Male to RJ 45 Female Modular Adapter ?
http://www.cable-trader.co.uk/items/db25-male-to-rj45-female-modular-adapter

I can not see clearly the pin configuration for the interface that you've pointed out.
If you or any one know where i can get the pin config for this cable http://www.cpexonline.com/images/cp_cna003.jpg that would be great. I hope this works :D


Thanks
 
Hi jrwb4gbm,

If i use DB9 Female to RJ 45 Female Modular Adapter http://www.cable-trader.co.uk/items/db9-female-to-rj45-female-modular-adapter .Will it works?
OR
Should i use DB25 Male to RJ 45 Female Modular Adapter ?
http://www.cable-trader.co.uk/items/db25-male-to-rj45-female-modular-adapter

I can not see clearly the pin configuration for the interface that you've pointed out.
If you or any one know where i can get the pin config for this cable http://www.cpexonline.com/images/cp_cna003.jpg that would be great. I hope this works :D


Thanks

I don't know if these adapters will work or not.
The comm port in the picture (post # 10) that you should use is the one that is nearest the tip of the measuring stick and it is a DB9 male. The red port DB25 female looks like a parallel printer port. Do not use it. I am trying to figure out how to build you a cable that does not need the D100CPM232 interface adapter. If you want to just buy one, try this link:
http://www.santaclarasystems.com/manufacturers/cutler-hammer/D100CPM232.html

P.S. I sent you a PM, please read it and reply by PM, thanks.
 
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Hi jrwb4gbm

Is there any way you can re draw the wiring diagram,so i can easierly see what i have to solder to the IC.Im not an expert in electronic devices so this diagram is abit confuse for me to understand.
I've contact my local electronic part supplier and i show them the IC chip that you have quoted in the email. Im just waiting for thier answer and i hope they have it.
I also have contacted Eaton near the place where i live,they told me they dont have this interface adapter anymore and they couldnt find the wiring configuration for this adapter.



I could not figure out how to make a direct cable without using an LT1081 chip.

Here is another link for how to use the programming software:
http://www.toshiba.com/ind/data/tag_files/EXPDD2040%20Manual_510.pdf

Also here is the Toshiba part number:
EX2040CNV232
 
Attached is a simplified drawing of the interface. You will probably need to refer to the original drawing for more details.

Picture 009.GIF
 

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