G303 RIO (REMOTE I/O) AND LOW END RTU

Transcription

1 G3 TECHNOLOGIES, INC. G303 RIO (REMOTE I/O) AND LOW END RTU USER DOCUMENTATION / FUNCTIONAL SPEC. Introduction: The G303 is one of several RIO (Remote I/O) products from G3 Technologies designed to fill a low-end "niche" in the SCADA and Industrial Automation market. These products offer various I/O combinations using a common PIC processor based core design. They are low cost units providing wired or wireless I/O expansion for PLC, RTU or PC based control and monitoring systems. Targeted applications are as follows: Low-end RTU for SCADA systems requiring little or no data manipulation at the RTU. Local or remote I/O expansion for a SCADA RTU. Local or remote I/O expansion for PLC or PC based automation or monitoring systems. Wired or wireless data communications. Replacement of existing obsolete non-intelligent RTUs. Because of the use of a common core design, custom configurations of I/O or other features can be developed with minimal development time and cost. General Description: The G303 is a single-board RIO unit offering the following combination of I/O signals and data communications: 8 ea. Digital Inputs (contact closure) 4 ea. Digital Outputs (relay contacts) 4 ea. Analog Inputs, plus internal power supply voltage monitor. 1 ea. Pulse Input (turbine or pulse meter). Totalizer and Rate. 1 ea. Modbus serial data port: RS485 plus plug-on option of Spread Spectrum Radio, FSK modem or RS232. By using wide-spread industry standards (RS485 and Modbus) for serial data communications, the G303 is easily integrated into many common control / monitoring systems. Since the unit is designed for the simple task of reading inputs and driving outputs using pre-defined Modbus functions, it requires no software configuration. It can be treated as "another Modbus end-device". The G303 is also a low-power and environmentally tolerant device, making it suitable for Solar powered applications and outside installations. It is packaged for panel or DIN rail mounting, but can also be supplied in a stand-alone Nema 4 rated package ready for field installation. HARDWARE DEFINITION: Physical Form: The G303 is a packaged unit with the following features: 1. The board is a 2 layer PCB with all components on the top, and measures 4" x 7" 2. The PCB is packaged in a metal enclosure with the wire terminals exposed. The cover is silk-screened with name, model number and termination labels. Overall size is approximately 4" x 8" x 1.5". 3. The unit has mounting holes on both ends for flat panel mounting. Optional TS-35 DIN rail mounting is available. 4. Field wiring terminations are along both long sides of the unit, and are plug-in screw-clamp "Phoenix" type terminals with vertical screw, vertical plug-in and horizontal wire entry. Terminations on the left are Analog Inputs, Meter (pulse) Input and Digital Inputs. On the right are RS485 serial port, Power Input and Digital Outputs. 5. When the MaxStream Spread Spectrum Radio is used, it plugs onto the face of the G303 board (inside the enclosure) and the RPSMA antenna connector is exposed at the end of the unit. Environmental: 1. Operating temperature, including SS Radio: -40 to +85 degrees C. 2. Relative humidity: 10% to 90%, non-condensing. Surge Withstand: All I/O and Power connections to the unit incorporate transient voltage protection to meet or exceed IEC minimum standards for ESD, Fast Transient and Lightning Surge tolerance. Agency Approvals: The G303 RIO board is designed to comply with UL and CSA requirements for Class I, Division II, Group D hazardous location usage. Certification is pending. The G303 meets applicable FCC Part 15 criteria for RF emission and susceptibility.

2 PCB Power: Power will typically be supplied from a 12 volt battery-backed power supply (like the G304 industrial temp. UPS). 1. Input power (Vcc): to +16.0Vdc normal operation. Self-resetting 1.0 amp fuse. 2. Input voltage monitor: (See Analog Input section below) 3. Average current draw (without radio): 15 12Vdc 4. Three wire terminations: +Supply (Vcc), -Supply (GND), EGND (GND) Digital Inputs: The G303 provides eight (8) Digital Inputs. They are activated by pulling the signal line to ground (battery common) either by a metallic contact or by an open-collector transistor. Ten (10) screw terminals are provided for Digital Inputs. They are DI-1, DI-2, DI-3, DI-4, DI-5, DI-6, DI-7, DI-8, GND, GND. Analog Inputs: The G303 provides four (4) single-ended Analog Input (AI) channels for field use, and one (1) internal AI to monitor the Power Supply Input (Vcc). All five channels are Modbus readable. The AI characteristics are as follows: bit resolution 2. Overall accuracy on AI 1-4, +/- 0.25% over full operating temperature range. 3. DIP switch selectable 250 ohm (0.1%, 3 watt, wire wound) input resistor on AI Input low pass RC filter <1000Hz. 5. Analog input voltage range: 0-5Vdc (or 0-20mA with 250 ohm resistor). 6. Over-voltage tolerance on AI 1-4: +/-24 Vdc. 7. On-board +24V DC/DC converter for transducer excitation (Vx). Self-resetting 100mA fuse. Optional energy limiting resistors. 8. Transducer excitation voltage (Vx) is available on a screw terminal with each Analog Input, and is jumper selected to be either +24 volts or power supply voltage. 9. AI 1-4 have field wire terminations as follows: Vx, AI 1, AGND, Vx, AI 2, AGND, Vx, AI 3, AGND, Vx, AI 4, AGND. 10. The internal AI (AI 5) converts 0-16Vdc power supply to 0-5 volt analog signal, with +/- 1% accuracy. 11. The A/D Converter uses a synchronous serial interface to the processor. Pulse Totalizer / Flow Rate / Event Capture Input: The G303 has one (1) specialized pulse input. Modbus registers for Totalized Count (32bit) and Pulse Rate in both Pulses per Second (PPS) and Pulses per Minute (PPM) are provided. This input is also useful for capturing a short duration pulse event. The Modbus registers are initialized to zero. Screw terminals are provided for + and - Pulse signal. DIP switch options (S1-5, S1-6, S1-7) provide input conditioning for four (4) types of pulse input signals. They are as follows: 1. Turbine meter with inductive pick-up: Differential input w/ 20K ohm input impedance for AC sine wave input (no DC component). Input sensitivity of 80mV p/p at 10Hz, and 2.0V p/p at 2.5KHz. (S1-5 off, S1-6 off, S1-7 off) 2. Logic level pulse signal: Single-ended, 0-5 to 0-12V signal level, switching point approx. 20% of Vcc, 1.5KHz (symmetrical) freq. range. (S1-5 off, S1-6 on, S1-7 off) 3. Open-collector transistor or reed switch: Single-ended, on-board 10K ohm pull-up to Vcc, switching point approx. 20% of Vcc, 1.5KHz (symmetrical) freq. range. (S1-5 on, S1-6 on, S1-7 off) 4. Dry mechanical contact: 7mS contact de-bounce, Single-ended, on-board 10K ohm pull-up to Vcc (wetting voltage), switching point approx. 20% of Vcc., 0-60Hz (symmetrical) freq. range. (S1-5 on, S1-6 on, S1-7 on) Digital Outputs: The G303 has four (4) Relay outputs, each with form-c contacts at the screw terminals. The relay outputs can be either latched or timed. In the latched DO register, bits 1-4 correspond to DOs 1-4. When a "1" is written to one or more of these bits, the corresponding relay(s) is energized, and when "0" is written the corresponding relay(s) is de-energized. For timed DOs, each of the four DOs has its own 16 bit register. A single write message can load one or more (consecutive) of the timed DO registers. They are "count-down" registers decremented every 100mS (0.1 sec.). Any non-zero value written to these registers will energize the corresponding relay, and the relay will then de-energize when it decrements to zero. A timed DO can be set from 100mS up to 1.8 hrs (+0 / -100mS). In addition to pulsed DO or "Jog" functions, this feature can also be used as a "Communication Loss DO Timeout" feature. Periodically writing a value to the Timed DO register that is greater then the update rate will keep a DO relay energized. If communications is interrupted, then the Timed DO register will time out and de-energize the corresponding DO relay. The Timed DO registers are logically "OR'd" with the Latched DO register bits. Therefore, if a bit is set in the Latched DO register, then the DO relay will be energized regardless of the value in the Timed DO register. 2

3 The relay contacts are UL rated for 10A at 30VDC resistive, 10A at 250VAC general use, 1/4HP 120VAC, 1/2HP 250VAC, B300 pilot duty, and Q300 pilot duty. Each relay offers 4000 volt contact-to-coil isolation for surge protection. Serial Comm. Port: The G303 has one (1) comm. port, and it uses Modbus RTU slave protocol. Wired and wireless configurations are supported as follows: 1. Wired communications: RS485 (DIP Switch selected 2 wire or 4 wire) on screw terminals. 2. Wireless communications: The G303 RIO has provision for an optional Spread Spectrum radio integral to the unit. A variety of features with SS Radio: 900MHz or 2.4GHz, 9600 or 19.2K baud, RF power from 1mW to 1W. Radio's power-down pin can be controlled by the processor for custom applications, and is DIP switch enabled (S1-8). Other power-down options are available. When using radio communications with the G303, the Rx & Tx data are available at the RS485 terminations so that the radio communications can support additional G303 units or other RS485 / Modbus devices. Other communication interfaces are offered as plug-on options in place of a SS radio (i.e. RS232, Bell 202 modem, FSK modem for VHF/UHF Splinter freq. radios [Amocams compatible], etc.). Two DIP switch positions select one of four Baud rates (600, 1200, 9600, 19.2K) for the comm. port. The data structure is 8N1 asynchronous. S3-3 S3-4 BAUD OFF OFF 600 OFF ON 1200 ON OFF 9600 ON ON An eight (8) bit Modbus device address is set with DIP switches on the PCB (S2-1 through S2-8). CPU: The PIC Processor has internal RAM and in-circuit-programmable FLASH memory. All code is stored in non-volatile FLASH memory. Diagnostics: 1. The unit has 4 LEDs that monitor activity. They are Receive Data (Rx), Transmit Data (Tx), Power monitor, and a CPU driven LED to indicate CPU activity. 2. There are also 13 LEDs that monitor the I/O (Digital inputs, Pulse input, and Digital outputs). 3. A pair of pins are provided on the PCB for a complete hardware reset (when shorted). SOFTWARE DEFINITION: (Firmware Version 1.x) Modbus Implementation The Modbus Slave RTU mode protocol is used. Communications parameters are eight data bits, no parity bit, and one stop bit (8N1). The Baud rate (600, 1200, 9600, 19.2k) is selected by two DIP switch positions. See Serial Comm. Port section for switch position table. The Modbus slave address is read from the 8-bit DIP switch located on the board. The following Modbus function codes are supported: Function Code 03 Multiple Holding Register Read (for data read) Function Code 06 Single Register Write (for latched DO s or single timed DO) Function Code 16 (hex 10) Multiple Register Write (for timed DO s) If the Modbus master attempts to perform a function not listed, the slave returns an Illegal Function exception response. Consecutive register reads return values for Digital Inputs, Analog Inputs 1 through 5 respectively, Pulse Input Totalizer, Pulse Input PPS Rate, Pulse Input PPM Rate, software version number, Latched DO register value and "time remaining" values for Timed DO #s 1-4. The fifth analog channel monitors the power supply input voltage through an on-board resistor divider network. Zero analog value equals 0.0 volts DC, and 4095 (hex FFF) analog value equals 16.0 volts DC. The software returns raw analog and digital input values. No data conversion is done in the unit. Data values are right justified in the register. 3

4 Each register is a 16-bit value. The data is formatted with the high byte followed by the low byte. Unimplemented bits are zerofilled. Register numbers are zero based (i.e., register #3001 as shown below is the first register in the 3000 range, and is addressed as #3000 or hex "BB8"). The controller returns an Illegal Data Address exception response if the Modbus master attempts to read a register that is not in the register map listed below. Data integrity checking uses 16 bit CRC that follows the CRC-CCITT specification. The version number high byte contains the major version number and the low byte contains the minor version number. For example, if register 3012 contains 0105 hex, it can be viewed as version 1.5 (which is the current firmware release). Modbus Register Map Register # Description Read/Write 3001 Digital Input bits Read Only 3002 Analog Input #1 Read Only 3003 Analog Input #2 Read Only 3004 Analog Input #3 Read Only 3005 Analog Input #4 Read Only 3006 Analog Input #5 Read Only 3007 Meter Total - Lower 16 bits Read Only 3008 Meter Total - Upper 16 bits Read Only 3009 Meter Rate, PPS Read Only 3010 Meter Rate, PPM - Lower 16 bits Read Only 3011 Meter Rate, PPM - Upper 16 bits Read Only 3012 Code Version # Read Only 3013 Digital output bits, latched Read/Write 3014 Timed Digital Output #1 Read/Write 3015 Timed Digital Output #2 Read/Write 3016 Timed Digital Output #3 Read/Write 3017 Timed Digital Output #4 Read/Write Modbus message examples (data values shown in HEX): Multiple Register Read Regs 3001 (0BB8 hex) (0BC8 hex). Read all Data Master Tx: B B C7 (addr 01, funct 03, start reg 0BB8, # of regs 0011, CRC 07C7) Slave Tx: E C E6 D0 (addr 01, funct 03, byte count 22, reg values, CRC E6D0) Single Register Read Reg (0BBD hex). Read Analog Input #5 internally monitors Power Supply Voltage Master Tx: B BD A (addr 01, funct 03, start reg 3006 [0BBD], # of regs 0001, CRC 160A) Slave Tx: E C0 BC 74 (addr 01, funct 03, byte count 02, reg 3006 value 0EC0, CRC BC74) Single Register Write Reg (0BC4 hex). Latch Digital Outputs #s 2 & 4 Master Tx: B C4 00 0A 4A 14 (addr 01, funct 06, reg 0BC4, write value 000A, CRC 4A14) Slave Tx: B C4 00 0A 4A 14 (addr 01, funct 06, reg 0BC4, stored value 000A, CRC 4A14) Multiple Register Write Regs 3014 (0BC5) (0BC8). Timed DO s #1=200ms, #2=400ms, #3=600ms, #4=800ms Master Tx: B C B (addr 01, funct 10, start reg 0BC5, # of reg 0004, byte count 08, DO#1 0002, DO#2 0004, DO#3 0006, DO#4 0008, CRC 907B) Slave Tx: B C D3 D3 (addr 01, funct 10, start reg 0BC5, # of regs written 0004, CRC D3D3) PC / LAPTOP COMMUNICATIONS SUPPORT: Interconnect: For wireless communications with G303 RIO units with internal SS radio, a compatible Radio Modem Model G306 is available with RS232 interface for direct connection to a serial port on the PC (or other Modbus master polling device). To be compatible, the SS Radios must use the same frequencies (900MHz or 2.4GHz), the same baud rate (9600 or 19.2K baud) and be configured for the same "Net Code". The Net Code is set at Zero (0) unless otherwise specified. The G306 Radio Modem is powered by 12VDC (10.5 to 15VDC), requires no configuration, and uses only data (no hand shaking) on the RS232 interface. When communicating wireless, the SS Radios are transparent to the system. 4

5 For support of licensed UHF or VHF radios (including splinter frequencies), FSK Modems are available (G303 internal and stand-alone Model G305). Optional RS232 interface is also available on the G303 for use with radios or modems requiring it. For wired communications between a PC and multiple G303 RIO units, the G303's RS485 port may be used along with an RS485 converter on the Serial Port of the PC. For a single G303, the RS232 option may be used to interface directly to the PC's serial port. Windows based DEMO/TEST utility: "G303 Demo" is available from G3 Technologies for customer demo as well as for bench testing. It is a simple Windows based utility that serves as a Modbus Master to communicate with the G303. It will interrogate the unit using a selected RTU address, and display the returned I/O data. It will also send commands to activate the Digital Outputs. LIMITED WARRANTY: One year from date of purchase, warranted against defects in material and workmanship. See full warranty statement for details. ORDERING INFORMATION: (Other Model configurations are available) Part Number Sensor Voltage (Vx) Energy Limiting: 0 = None 1 = Energy Limited Serial Data Interface Type (in addition to RS485): 00 = None 04 = 9xStream X09-009NSI, 9600 baud 900MHz SS Radio, 100mW, Ind. Temp. 06 = 9xStream X09-019NSI, baud 900MHz SS Radio, 100mW, Ind. Temp. 08 = 24xStream X24-009NSI, 9200 baud 2.4GHz SS Radio, 100mW, Ind. Temp. 10 = 24xStream X24-019NSI, 19,200 baud 2.4GHz SS Radio, 100mW, Ind. Temp. 12 = 9xCite XC09-009NSI, 9600 baud 900 MHz SS Radio, 1mW, Ind. Temp. 14 = 9xTend, XT09-NSI, 9600 baud 900MHz SS Radio, 1W, Ind. Temp. 50 = FSK Modem, 600 baud for VHF/UHF splinter freq. radios 60 = RS-232 Interface Normally Stocked P/Ns: , , Nema 4X rated packages also available. For pricing and availability, as well as for other information, please contact G3 Technologies, Inc. Contact Information: G3 Technologies, Inc W. 239 th Street Louisburg, KS ph , fax , sales@g3ti.com. Additional information is available on our web site. Mounting Dimensions #8 Pan Head screws recommended for mounting Copyright 2006, G3 Technologies, Inc. G3 Technologies, Inc. reserves the right to revise these specifications at any time without notice. G303 User Doc: updated 7/10/06 5