User Manual 905U Wireless I/O Module 105S Serial I/O Module For 905U-C and 905U-D products, refer to separate User Manuals ELPRO Technologies Pty Ltd, 9/12 Billabong Street, Stafford Q 4053, Australia. Tel: +61 7 33524533 Fax: +61 7 33524577 Email: sales@elprotech.com Web: www.elprotech.
905U Wireless I/O Module 105S Serial I/O Module User Manual Thank you for your selection of the 905U / 105S module for your I/O needs. We trust it will give you many years of valuable service. ATTENTION! Incorrect termination of supply wires may cause internal damage and will void warranty. To ensure this product enjoys a long life, double check ALL your connections with the user’s manual before turning the power on.
Contents FCC Notice: 905U Wireless I/O Module This user’s manual is for the ELPRO 905U wireless I/O module. This device complies with Part 15.247 of the FCC Rules. Operation is subject to the following two conditions: 1) This device may not cause harmful interference and 2) This device must accept any interference received, including interference that may cause undesired operation. This device must be operated as supplied by ELPRO Technologies.
905U Wireless I/O Module 105S Serial I/O Module User Manual Important Notice ELPRO products are designed to be used in industrial environments, by experienced industrial engineering personnel with adequate knowledge of safety design considerations. ELPRO radio products are used on unprotected license-free radio bands with radio noise and interference.
Contents Limited Warranty, Remedies Disclaimer and Limitation of ELPRO products are warranted to be free from manufacturing defects for a period of 2 years from the effective date of purchase. The effective date of purchase is decided solely by ELPRO Technologies.
905U Wireless I/O Module 105S Serial I/O Module User Manual How to Use This Manual To receive the maximum benefit from your 905U/105S product, please read the Introduction, Installation and Operation chapters of this manual thoroughly before putting the product to work. Chapter Four Configuration explains how to configure the modules using the Configuration Software available. Chapter Five Specifications details the features of the product and lists the standards to which the product is approved.
Contents CHAPTER THREE OPERATION.....................................................................................................24 3.1 POWER-UP AND NORMAL OPERATION ...........................................................................................24 3.1.1 Communications ..................................................................................................................25 3.1.2 Change of state conditions.............................................................................
905U Wireless I/O Module 105S Serial I/O Module Chapter One User Manual INTRODUCTION 1.1 General The 905U & 105S range of I/O modules has been designed to provide standard “off-the-shelf” telemetry functions, for an economical price. Telemetry is the transmission of signals over a long distance via a medium such as radio or twisted-pair wire. Although the 905U/105S is intended to be simple in its application, it also provides many sophisticated features.
Chapter One Introduction 905U modules. 105S modules may be used for serial I/O applications, or as I/O expansion for 905U modules. • The 905U-C module provides an interface between host devices such as PLC’s or SCADA computers, and a wireless I/O system comprising 905U modules. The 905U-C allows 905U modules to act as remote wireless I/O for the host devices. For more information, refer to the 905UC User Manual.
905U Wireless I/O Module 105S Serial I/O Module User Manual Input signals connected to a module are transmitted to another module and appear as output signals. These input signals may also be configured to appear as “inverted” signals on the output. A transmission occurs whenever a "change-of-state" occurs on an input signal. A "change-of-state" of a digital or digital internal input is a change from "off" to "on" or vice-versa.
Chapter Two Installation Chapter Two INSTALLATION 2.1 General The 905U/105S module is housed in a rugged aluminium case, suitable for DIN-rail mounting. Terminals are suitable for cables up to 2.5 sqmm in size. All connections to the module should be SELV only. Normal 110/220/240V mains supply should not be connected to any input terminal of the module. Refer to Section 2.3 Power Supply. Before installing a new system, it is preferable to bench test the complete system.
905U Wireless I/O Module 105S Serial I/O Module User Manual antenna is a larger obstruction than a group of trees further away from the antenna. The 905U modules provide a test feature which displays the radio signal strength. Line-of-sight paths are only necessary to obtain the maximum range. Obstructions will reduce the range however, but may not prevent a reliable path. A larger amount of obstruction can be tolerated for shorter distances.
Chapter Two Installation loss. For example, a 6 element Yagi with 70 feet (20 metres) of Cellfoil has a net gain of 4dB (10dB – 6dB). Connections between the antenna and coaxial cable should be carefully taped to prevent ingress of moisture. Moisture ingress in the coaxial cable is a common cause for problems with radio systems, as it greatly increases the radio losses.
905U Wireless I/O Module 105S Serial I/O Module 2.2.2 User Manual Yagi antennas. A Yagi antenna provides high gain in the forward direction, but lower gain in other directions. This may be used to compensate for coaxial cable loss for installations with marginal radio path. The Yagi gain also acts on the receiver, so adding Yagi antennas at both ends of a link provides a double improvement. Yagi antennas are directional.
Chapter Two Installation 2.3 Power Supply The 905U/105S power supply is a switch-mode design which will accept either AC or DC supply. The module may also be powered from a solar panel without an external solar regulator. The module accepts supply voltages in the following ranges : 12 - 24 volts AC RMS or 15 - 30 volts DC at the “supply” terminals, or 10.8 -15 volts DC at the “battery” terminals. The power supply should be rated at 1.5 Amps and be CSA Certified Class 2. 2.3.
905U Wireless I/O Module 105S Serial I/O Module User Manual Upon failure of the normal supply, the module may continue to operate for several hours from a backup battery. The module includes battery charging circuits for charging up to a 12 AHr sealed lead acid battery. The battery is connected to the "BAT+" (positive) and "GND" (negative) terminals. The positive lead from the battery should be protected with a 2A fuse, installed as near to the battery terminal as possible.
Chapter Two Installation achieve this, the input power supply must be above 15VAC or 17VDC. Using these figures, it can be determined whether there is enough supply for more than one module - allow 100mA for recharging a battery. For example, assume there is a 905U-1 module and a 105S-1 module at the same location. The total I/O at the location is 3 analog inputs, 6 digital inputs and 4 digital outputs.
905U Wireless I/O Module 105S Serial I/O Module User Manual provides 4 to 16 inputs with 3000 volt surge protection. All inputs are suitable for voltage free contacts (such as mechanical switches) or NPN transistor devices (such as electronic proximity switches). PNP transistor devices are not suitable. Contact wetting current of approximately 5mA is provided to maintain reliable operation of driving relays. Each digital input is connected between the appropriate "DI" terminal and common "COM".
Chapter Two Installation Digital outputs may be configured to individually turn off if no command message is received to that output for a certain period. This feature provides an intelligent watch dog for each output, so that a communications failure at a transmitting site causes the output to revert to a known state. See section 4.4 Changing User Options for further details. The output circuit is connected to the appropriate pair of "DO" terminals.
905U Wireless I/O Module 105S Serial I/O Module User Manual A 24VDC supply is available on the module for powering the analog transducer loops. In this case, the analog loop should be connected between a "AI 1-" terminal and "COM" ( for the first analog input) or "AI 2-" ( for the second analog input), and so on for other inputs. The positive terminal ("AI 1+" or "AI 2+", etc) should be connected to "+24V".
Chapter Two Installation received to that output for a certain period. . See Chapter 4 Configuration for further details. 2.4.6 Pulse Input (905-1) For the ”-1” module, digital input 1 may be configured as a pulse input (max rate 100 Hz, min. off time 5 ms). In this mode, both the pulse rate and the pulse count are available for mapping to a remote output.
905U Wireless I/O Module 105S Serial I/O Module User Manual of up to 100 Hz. The outputs accurately recreate the pulses counted at pulse inputs at a ”-1”, ”-2” or “-4” module. Although the count is accurately re-created, the rate of output pulses may not accurately reflect the input rate. The actual input pulse rate may be configured to appear at an analog output if required. Note that the pulse rate and accumulated value will remain accurate even if a period of communications failure has occurred. 2.4.
Chapter Two Installation used to interconnect modules to reduce potential Radio Frequency Interference (RFI). An RS485 network should be wired as indicated in the diagram below and terminated at each end of the network with a 120 ohm resistor. The 905U modules include a terminating resistor on-board. If the 905U module is the first or last module in the RS485 chain, then the terminating resistor may be connected by operating the single DIP switch in the end-plate next to the RS485 terminals.
905U Wireless I/O Module 105S Serial I/O Module User Manual Chapter Three 3.1 OPERATION Power-up and Normal Operation When power is initially connected to the module, the module will perform internal diagnostics to check its functions. The following table details the status of the indicating LED’s on the front panel under normal operating conditions.
Chapter Three 3.1.1 Operation Communications If transmissions are not successful (radio or serial), then the module will re-try up to four times at random intervals to transmit the message.
905U Wireless I/O Module 105S Serial I/O Module User Manual If communications is still not successful, the “Comms Fail” internal status will be set. In the default configuration, this will have no consequence and the module will continue to attempt to transmit to the remote module every ten minutes. For critical applications, the “comms fail” status can be configured to be reflected to an output on the module for alert purposes.
Chapter Three Operation Analog Change-of-state A "change-of-state" for an analog input, battery voltage or pulse input rate is a change in value of the signal of 3% (configurable) since the last transmission. Note that the sensitivity of 3% refers to 3% of the analog range, not 3% of the instantaneous analog value. That is, if an analog input changes from 64% (14.24 mA) to 67% (14.72 mA), a "change-of-state" will be detected. This “change-of-state” sensitivity is configurable between 0.8% and 75%.
905U Wireless I/O Module 105S Serial I/O Module User Manual In general, the following may be used as a rule of thumb for calculating the appropriate sensitivity required for a given application: Instantaneous change of 2 x sensitivity on input → 3 second output response Instantaneous change of 10 x sensitivity on input → 5 second output response The analog inputs have 15 bit resolution and 0.016mA accuracy. Pulse input change of state Pulse input counts do not use “change-of-state” transmissions.
Chapter Three Operation case, the output pulses are effectively 1 minute behind the input pulses. These update times may be changed by the user. The pulse output update time should not be set to be more than the pulse input update time. Note that the maximum pulse rate for both inputs and outputs is 100Hz. As well as accumulating the pulse input, the module will also calculate the rate of pulses.
905U Wireless I/O Module 105S Serial I/O Module User Manual after the first repeater, then the source module CF status will not set. To indicate comms status on this type of link, the “Reset Output” function should be used. 3.1.6 Resetting Outputs Each digital and analog output may be individually configured to reset if that output has not received a change-of-state or an update message within a certain time period.
Chapter Three Operation reliable - poor radio paths will require re-try transmissions and will reduce the peak channel density. If there are other users on the radio channel, then this peak figure will also decrease. 3.2.3 Radio Path Reliability Radio paths over short distances can operate reliably with a large amount of obstruction in the path. As the path distance increases, the amount of obstruction which can be tolerated decreases.
905U Wireless I/O Module 105S Serial I/O Module User Manual each output. If a message has not been received for this output within this time, then the output will reset (off, in-active, “0”). We suggest that this reset time be a little more than twice the update time of the input. It is possible to miss one update message because of short-term radio interference, however if two successive update messages are missed, then long term failure is likely and the output should be reset.
Chapter Three Operation problem. 3. You should use separate outputs to indicate “comms OK” of different remote modules. 4. It is recommended that you set the reset time at #1 to more than twice the update time of the mapping at #2. This means that the comms OK output will only reset if #1 misses two consecutive updates from #2. 3.2.6 Testing and Commissioning We recommend that you set-up and test the system with all of the modules together before you install the modules.
905U Wireless I/O Module 105S Serial I/O Module Chapter Four User Manual CONFIGURATION 4.1 Introduction The modules are configured by connecting a computer (PC) using the Configuration Software program. The same software program is used to configure 905U-C modules - for more information, refer to the separate 905U-C User Manual. Each module is configured with a system address and a unit address.
Chapter Five 4.2 Specifications Easy Configuration Using Default Settings If your application requires only a single pair of modules, communicating via radio or serial link, default settings may satisfy your needs. If so, no configuration is required. Essentially, all inputs at Module A are reflected at the corresponding outputs at Module B. All inputs at Module B are reflected at the corresponding outputs at Module A.
905U Wireless I/O Module 105S Serial I/O Module User Manual For “-2” and “-3” modules, the default configuration is as follows :- Note that there is no default configuration for the “-4” modules.
Chapter Five Specifications 4.3 Configuration Software This chapter describes installation and operation of configuration software for the radio and serial telemetry modules. The configuration software runs on a conventional PC as a Windows application. The software creates a configuration file which can be loaded into a module via RS232. The configuration software also allows the configuration of a module to be loaded for display and modification.
905U Wireless I/O Module 105S Serial I/O Module User Manual 4.3.2 Program Operation Start the software by either clicking on the start bar and navigating to the Configuration menu or by running ESERIES.EXE in the directory selected in the setup stage. The Initial screen will appear. The configuration is performed for a complete system.
Chapter Five Specifications Loading configuration from an existing module To load the configuration from a module, connect the module to the PC via the RS232 cable and click on “Load Unit”. This will allow you to view the module configuration, change it, or copy it for another module - refer to section 4.3.3 for more information. Adding a new module to the system configuration To add a new module to the system configuration, click on “Units” on the left-hand menu and then “Add Unit”.
905U Wireless I/O Module 105S Serial I/O Module User Manual Configuring an individual module Double-click on a unit shown on the left-hand menu. The configuration options for each unit will appear. We recommend that you configure I/O mappings first, and then other options. Select “Mappings” and the following screen appears.
Chapter Five Specifications 1. The I/O mapping display will show all inputs at the selected module - both physical inputs and internal inputs. Select the input to be mapped. 2. If you wish to invert the mapping, select the “Invert Input” box. If you invert an input, then the output will be the reverse of the input. Analog I/O can also be reversed - 0mA will be 24mA, 4mA will be 20mA etc. Do not invert pulse inputs. 3.
905U Wireless I/O Module 105S Serial I/O Module User Manual It is possible to map a digital input to an analog output - the output will be maximum value when the input is on and minimum value when the input is off. It is also possible to map a analog input to an digital output - the output will be on when the input is equal or greater than 12mA and off when the input is less than 12mA. Every module should have at least one mapping configured.
Chapter Five Specifications analog - if analog, the output will go to maximum value. Although communication failure will activate the output, successful comms does not reset the output. You must use the “Reset outputs on comms fail” option (Refer to User Options section). Each remote module has a separate comms fail status - you enter a separate comms fail mapping for different remote addresses.
905U Wireless I/O Module 105S Serial I/O Module User Manual radio channel, which results in increased communication failures and poorer performance of the system. To change an update time, select “Update Times” on the left-hand menu and double-click the selected input. The update time will be shown in days:hours:minutes:seconds. Change the values in each field. The display also shows the maximum and minimum values.
Chapter Five Specifications then set again when the update message is received. We recommend that the reset time be a little more than twice the update time. To set an output reset time, select “Output Reset Times” on the left-hand menu and double-click the selected input. The update time will be shown in days:hours:minutes:seconds. Change the values in each field. The display also shows the maximum and minimum values.
905U Wireless I/O Module 105S Serial I/O Module User Manual Debounce time operates on the set-point status in the same way as digital inputs. To change a setpoint values, select “SetPoints” on the left-hand menu and double-click the selected Setpoint Status. Pulse Input Count Configuration PI1 of the -2 and -4 modules normally count up to 100Hz (as for the other PI’s), however can be configured to count up to 1000Hz.
Chapter Five Specifications Pulse Output Update Time Configuration The pulse output update time is the time period over which pulses are output after a PI update is received. It should be configured to correspond to the pulse input update time for the corresponding pulse input. This ensures that the pulse output rate matches as closely as possible the pulse input rate which it is reflecting. For example, if the PI update time is 1 minute, then the PO update time should also be 1 minute.
905U Wireless I/O Module 105S Serial I/O Module User Manual Programming Configurations to Modules To program a module : • Connect the cable from the PC’s serial port to the module serial port (see 2.4.10 for cable connections) • From the Utilities menu, select “Serial Port Setup” • Select the appropriate serial port (COM1 COM4) • Select the unit to be configured from the left-hand menu • Double-click “Program Unit”. Each module will need to be programmed individually. 4.3.
Chapter Five Specifications Chapter Five SPECIFICATIONS General EMC approval FCC Part 15A Radio standards FCC Part 15.247 902 – 928 MHz, 1W Housing 130 x 185 x 60mm DIN rail mount Powder-coated, extruded aluminium Terminal blocks Removable Suitable for 2.5 mm2 conductors LED indication Power supply, OK operation, digital I/O, RX and TX Operating Temperature -40 to 55 degrees C Humidity 0 – 99% RH non-condensing Power Supply Battery supply 11.3 - 15.
905U Wireless I/O Module 105S Serial I/O Module User Manual Expected line-of-sight range (subject to local conditions) 20 miles + @ 4W ERP 15 km + @ 1W ERP depending on local conditions Antenna Connector Female SMA coaxial Data transmission rate 19200 baud Serial Ports RS232 Port DB9 female DCE 9600 baud, no parity, 8 data bits, 1 stop bit RS485 Port 2 pin terminal block 9600 baud, no parity, 8 data bits, 1 stop bit, Typical distance 1 mile / 2km Data transmission On change-of-state + integri
Chapter Five Pulse Inputs Specifications 905U-1/105S-1 One 905U-2/105S-2 Four 905U-3/105S-3 None 905U-4/105S-4 Four Uses DI1. Max rate 100Hz, min. off-time 5msec. Uses DI1-4. Max rate of DI1 is 1000Hz, min. off-time 0.5msec Max rate of DI2-4 is 100Hz, min. off-time 5msec. Pulse Output 905U-1/105S-1 One 905U-2/105S-2 None 905U-3/105S-3 Four 905U-4/105S-4 Four FET output, 30 VDC 500mA max Max rate for 105-1 is100 Hz. Max rate for 105-3 is 1000 Hz. Pulse signal recreated, pulse rate avail.
905U Wireless I/O Module 105S Serial I/O Module Diagnostics On board diagnostics Page 52 User Manual Automatic check on startup Via RS232 terminal or laptop Input status Output test Incoming radio signal level Simple radio path testing © October 2001
Chapter Six Chapter Six Troubleshooting TROUBLESHOOTING 6.
905U Wireless I/O Module 105S Serial I/O Module User Manual Remove the cover in the front panel, and set the DIP switches as shown below. Hold down the red button for five seconds, or until the Rx LED glows yellow, release the Red button (the Rx LED now flashes), then press and release the Red button (the flashing Rx LED extinguishes). 0 0 1 0 0 0 0 0 0 0 0 0 0 0 0 0 Input signals may now be connected to the input terminals of the module.
Chapter Six Troubleshooting have to set up the connection parameters for future uses. Connect the module (ensure the RS485 port is disconnected first) to the PC using the same serial cable used for configuration. The diagnostics menu is accessed by setting all switches to ‘0’, and holding down the red button for approximately 5 seconds, until the RX LED lights continuously. One of the following menus will be displayed on the terminal : 105 V1.0 1052 V1.
905U Wireless I/O Module 105S Serial I/O Module User Manual low volts status (‘1’ for low volts ‘0’ for OK). "S" is the set-point status. P CNT, AI1, AI2, P RATE, and VBATT each represent 16 bit values, displayed as four hexadecimal digits. P CNT is the current value of the pulsed input counter. This value should increment each time ‘DI 1’ turns from OFF to ON. P RATE displays the current pulse rate at DI1.
Chapter Six Troubleshooting 905U-2/105S-2 Modules Digital Inputs DIN SETPNT 1234MSL123456 0000100111111 PULSED PIN1 PIN2 0000 0000 PIN3 0000 PIN4 0000 Analog Inputs VBAT 8138 PR1 4000 PR2 PR3 4000 4000 PR4 4000 AI1 0D3A AI2 0CD2 AI3 0CC7 AI4 0CC7 AI5 AI6 0CD4 0CC7 905U-3/105S-3 Modules ML 00 VBAT VSLR 9FA2 0000 905U-4/105S-4 Modules Digital Inputs DIN DIO PULSED 1234 123456789ABC MLS PIN1 PIN2 PIN3 PIN4 1001 010101010 001 101 0001 0001 0001 0001 Analog Inputs VBAT PR1 PR2 PR3 PR4 8DBE 0000
905U Wireless I/O Module 105S Serial I/O Module User Manual Example (105-1): >c Comms TX: 01FA8106008005C6727D44 Command message transmitted by this unit. 84 01FA8186C6E0E3 Acknowledge received from remote. 81 01FA860100800100009286 Message received from remote unit. TX: 01FA868100FCE4 Acknowledge message from this unit to remote. DO1 to DO8, DIO1 to DIO12 These options allow the user to set and clear digital outputs.
Chapter Six Troubleshooting Signal This option provides for testing the radio path between two 905U units for a suitable reliability margin. Although a pair of units may communicate successfully, radio communication may be affected by a range of influences, including atmospheric conditions, changing landscape, degradation of antennas or co-axial cable, low battery voltage etc. “Fade margin” is an indication of how far a radio path can deteriorate before communication becomes unreliable.
905U Wireless I/O Module 105S Serial I/O Module User Manual Chapter Seven WARRANTY & SERVICE We are pleased that you have purchased this product. ELPRO products are warranted to be free from manufacturing defects for a period of 2 years from the effective date of purchase. The effective date of purchase is decided solely by ELPRO Technologies.
Appendix A System Example Appendix A SYSTEM EXAMPLE The following example of a system is a comprehensive guide to using some of the features of the range and design of system. The example application is a pump station which supplies water from a reservoir to a tank station. Signals are transferred between the pump station and tank station by radio - the distance between the two stations is 10 km (6 mile), and the radio path is heavily obstructed by buildings and trees.
905U Wireless I/O Module 105S Serial I/O Module User Manual The following design points should be noted :• A test of the radio path between the pump station and the tank station indicated that the radio path would be reliable provided antennas were installed at 6 m above the ground. At each site, the coaxial cable would be approx 30 feet in length, so it was decided to use 6 element Yagi antennas with RG58 coaxial cable - the Yagi antennas would compensate for the loss in the cable.
Appendix A System Example Tank Station Configuration The 905U-2 module has the following configuration :- Note the following points in the configuration : • #1 is a repeater for communications between #2 and #96 • The pulse rate scaling for PIN1 has been set to 5 man_905-105_2.
905U Wireless I/O Module 105S Serial I/O Module User Manual Hz to match the maximum flow rate of the flow meter. Note that PIN1 has not been configured for "divide by 10" (for 1000 Hz pulse signals). • AIN1 (the level transducer) is mapped to AO1 at the 905U-3. The analog debounce has been set to 2 sec. This is because of concern of wave action on the surface of the tank causing un-necessary change transmissions.
Appendix A System Example Note the following points in the configuration: • Note that no repeater address is necessary between #1 and #96. • DIN2 (pump running signal) has two mappings - a mapping to DO1 at #2 (tank station) and DO2 at #96 (control station). When DIN2 changes, there will be two separate change messages transmitted one by radio to #2 and one by serial link to #96. • AIN1 (pump amps) is mapped to AO3 at #97 (control station).
905U Wireless I/O Module 105S Serial I/O Module User Manual • PO 3 has been configured as a PO. Its pulse output update time is the same as the PI update time at the remote module (both have been left at their default value of 1 minute). • Reset times have been selected for the analog outputs (21 minutes) but not the digital outputs. In the event of a system failure, the digital outputs will stay at their last correct status, but the analog outputs will reset to 0 mA.
