RIO User`s Guide - G3 Technologies
Contents
1. 1L me s m s Vx T m 4 WIRE 2 WIRE e sei ahh wren im DIP Switch 3 e GND Ey Md Vx n 2 01 GND sig 2 ws WE eae A A C GND 10 5 15 VDC V Power Input Vx SELECT SUPPLY Vx select jumper J14 oo oro one ga u 2 0 5V 0 20mA SEPI BiP Swich 3 Al 4 c E DIP Switch S1 E DIFF SINEWAVE i Mabe Bh S 32 MIG PI10Hz 5KHz 0 10Hz g imt re E RADIO PWR ON o PWR SAVE o PULSE PULSE TXD r Pulse Input ij INPUT D e DIR DI 1 o DI 2 DI 2 PWR e DI 3 DI 3 CPU g a Di 4 D jM Digital Outputs Digital Inputs DI 5 DI 5 Status LEDs DI 6 DI 7 DI 8 GND GND e DI 6 DI 7 DI 8 O COM L NO r NC o COM LL NO G3 Technologies Inc www g3ti com Figure 1 e e 8 6 G303 User s Guide 2010 01 28 Specifications Data Communications Serial Data Comm Data Rate throughput Modbus Address Slave Comm Fail Action Modbus RTU Slave mode protocol 8N1 bite structure and selection of 600 1200 9600 amp 19 2K baud rate Integrated options are 1 RS485 only for wired multi drop networks 2 wire or 4 wire 2 900MHz or 2 4GHz FHSS radio and 2 or 4 wire RS485 expansion 3 FSK Modem for interface to external audio input radios 4 RS232 DTE DB9M for wired or 3rd party radio networks Per baud rate setting but with restrictions on wireless models 255 8 bit DIP Switch Device Addresses May be acc2. RIO User s Guide Industrial Remote I O Wired or Wireless Model G303 Revised 2010 01 28 G3 Technologies Inc Copyright 2004 2010 Table of Content Introduction ex xx ERES ones ARARNAR YA EA 1 Specifications sc c deos eae eee RR I RERO ew as 2 Input POWeF i ecc RE Re RES EAR Ene ded 4 GrOUNGING earar Ar een cU ERR aa CERRAR AA REG 4 Digital Input Description amp Wiring Diagram 5 Digital Output Description amp Wiring Diagram 6 Analog Input Description amp Wiring Diagram 7 Pulse Totalizer Rate Description amp Wiring Diagram 8 DIP Switch and Jumper Settings llle 9 LED Indicators amp Diagnostics llis 10 Modbus Registor Map lisse eee 11 Modbus Communications 00000 esee 13 Modbus Messages Examples 000000 eee eee eee 13 PC Master Communication Connections 14 Antenna amp RF Considerations 0 000 ee eee eee 14 Radio Configuration Using XCTU Config Utility 15 Mounting Dimensions 0 0000 e eren 18 Ordering Information 02 006000600 ese eee 18 Wartanty neenon dea eect dew dioe toad 18 Revision History niis rice tenps tiei Re eens beans 19 Contact Information G3 Technologies Inc 2536 W 239th St Louisburg KS 66053 Ph 913 963 7300 Fax 913 964 3010 E mail sales g3ti com Web site www g3ti com G303 User s Guide
3. used in model G303 080 XTO9 XTend 900MHz 1W selectable baud rate used in model G303 140 2 Select the Function Set Version Note that the XStream radio module requires Advanced RF Modes Version 5000 to support the radio repeater function The G303 is factory loaded with Version 5000 firmware and for standard operation it is compatible with the basic firmware Version 42B5 typical supplied previously However for a network requiring one or more radio repeaters all radios in that network must have Version 5000 firmware and be specially configured to support the repeater function See Advanced Configuration Options section below 3 Click the Show Defaults button This sets all of the parameters on the screen to their default values 4 Scroll down under Serial Interfacing to the parameter CS labeled DO2 Configuration on the XStream radio and GP02 Configuration on the 9XTend radio Click on this line item and from the drop down select 1 RS485 TX Enable Low This is the only parameter required to be non default for G303 RIO standard function 5 Change the Hopping Channel RF Net Code if you wish 6 Click the Write button to load the new Firmware and any altered parameter s into the G303 RIO 7 Click the Read button to read back the settings and confirm that they are correctly set Advanced Configuration Options The only advanced feature generally used is the Radio Repeater function Re
4. Range Test Terminal Modem Configuration Com Port Setup Select Com Port Communications Port COM1 Communications Port COM2 Baud 3500 Ad Flow Control NONE X Data Bits Parity Stop Bits Host Setup User Com Ports Network Interface API Enable API r AT command Setup ASCII Hex Command Character CC a Guard Time Before BT 1000 Guard Time After AT 1000 Modem Flash Update F No baud change Modem type Figure 8 mo cu COM2 Remote Configuration PC Settings Range Test Terminal Modem Configuration Modem Parameters and Firmware Write Restore Always update firmware Parameter View Profile Versions Clear Screen Save Show Defaults Load Modem XSTREAM Function Set Version 09 008 v HOPPING ADVANCED RF MODES vi 5000 3 Networking amp Security E 3332 ID Modem VID Bl 0 HP Hopping Channel Bl 0 DT Destination Address Bl FFFF MY Source Address Bl FFFF MK Address Mask H 0 RR Retries Bl 0 RN Delay Slots Bl 0 MD RF Mode lH 28 CB Connection Duration Timeout f 64 CE Connection Inactivity Timeout Bl 0 CM Connection message Bl FFFF TT Streaming Limit H 0 SY Time before Initialization 43 Serial Interfacing Bl 3 BD Interface Data Rate Ml 0 NB Parity Bl 1 RB Packetization Threshold Bl 32 RO Packetization Timeout Bl 40 PK RF Packet
5. See the Radio Configuration section for details In a situation where it is desired to implement a single radio repeater leg without impacting the radio configuration on the entire radio system radio repeating can be accomplished by connecting two RioLink radio modems back to back by inter connecting their RS232 485 ports and setting the hopping channel for the second RF leg to a different value than the radios on the main system Antenna Selection general guidelines For short distances less than 2000 in an open area or less than 100 within a building or wooded area a minimum antenna system can be used A low profile or dipole whip antenna mounted on the enclosure may be suitable For distances up to a few miles line of site a dipole antenna mounted eight or more feet above the ground is often suitable For longer distances a higher gain directional antenna like a yagi is recommended When using a pole mounted antenna it is recommended that a coax lightning suppressor be used and properly grounded for surge protection Also as the length of the coaxial cable increases it becomes more important to use low loss coaxial cable The radio s antenna connection is a reverse polarity SMA female RPSMA F possibly requiring an adapter cable available from G3 Technologies Radio Path Evaluation Evaluation of a radio path can be done by using a PC running the XCTU radio configuration utility and two RioLink radio modems This is a convenien
6. digital converter for all of the analog inputs is 12 bits providing a 0 4095 decimal count 0x0000 0x0FFF for zero to full scale inputs Al1 4 input signal type selection can be 0 5V or 0 20mA For example with Al1 selected as a 0 5V input type and a 2 5V signal is applied register 3002 value will be 2047 0xO7FF Al5 monitors power supply voltage V and has a range 0 16V 0V 0x0000 16V 20xOFFF For example with V 12 0Vdc register 3006 value will be 3071 OxOBFF Register values are raw no conversion and are right justified G303 User s Guide 2010 01 28 11 Register 3007 3008 Pulse Input Totalizer The pulse input totalizer is a 32 bit long word stored in two 16 bit registers The register values are stored in volatile memory and do not hold their value when power is turned off At power up the pulse totalizer registers are reset to a value of zero Register 3009 Pulse Input Rate Pulses per Second PPS The PPS pulse rate value represents the number of counts that the totalizer has incremented within the previous second and is updated once every second Register 3010 3011 Pulse Input Rate Pulses per Minute PPM The PPM pulse rate is a 32 bit long word stored in two 16 bit registers The value in these registers represents the number of counts that the totalizer has incremented within the previous minute and is updated once every second For PPM pulse rates of more than 65 535 OxFFFF both upper and lower registers
7. on i e If the first and third switches labeled with values of 1 amp 4 respectively are turned on the address value 1 4 address 5 DIP Switch S2 Bit Value Switch Positions sum for Addr S2 1 S2 2 S2 3 S2 4 S2 5 S2 6 S2 7 S2 8 RS485 SERIAL PORT CONFIG DIP switch S3 positions 1 2 For 4 wire RS485 factory default both switches are off and for 2 wire RS485 both switches are on BAUD RATE SELECT DIP switch S3 positions 3 4 Baud rates of 600 1200 9600 and 19 2K can be selected Factory default is 9600 baud 83 3 on NOTE When using a RIO model with integrated SS Radio the baud rate setting on the DIP switches must match the baud rate of the radio See Radio Configuration section later in this document Baud Rate Bit 1 S3 4 Bit 2 53 3 600 OFF OFF 1200 ON OFF LED INDICATORS AND DIAGNOSTICS The POWER LED remains on whenever the unit is powered up The CPU STATUS LED blinks every 2 seconds during normal operation If the unit fails to initialize upon power up or if an internal error occurs the CPU Status LED will be on continuously The TXD and RXD LEDs annunciate the transmit and receive data communications All of the DIGITAL I O are annunciated with LEDs including 1 Pulse Input 8 Digital Inputs and 4 Digital Outputs Each of the I O LEDs is turned on when the corresponding I O signal is active Complete hardware reset can be done by power cycling the unit G303 User s Guide 2
8. shown in HEX Read Multiple Register Regs 3001 0x0BB8 3017 OxOBC8 Read all Data Master Tx 0103 0B B8 00 11 07 C7 addr 0x01 funct 0x03 start reg OxOBB8 of regs 0x0011 CRC 0x07C7 Slave Tx 01032200 00 00 00 00 00 00 00 00 00 OE C1 00 00 00 00 00 00 00 00 00 00 01 07 00 00 00 00 00 00 00 00 00 00 ED 68 addr 0x01 funct 0x03 byte count 0x22 reg 13001 3017 values CRC OxED66 Read Single Register Reg 3006 OBBD hex Read Power Supply Voltage Al 5 Master Tx 01 03 0B BD 0001 16 0A addr 0x01 funct 0x03 start reg 3006 OxOBBD of regs 0x0001 CRC 0x160A Slave Tx 0103020E C1 7D B4 addr 0x01 funct 0x03 byte count 0x02 reg 3006 value OxOEC1 CRC 0x7DB4 Write Single Register Reg 3013 0x0BC4 Latch Digital Output s 2 amp 4 Master Tx 01 06 0B C4 00 OA 4A 14 addr 0x01 funct 0x06 reg 3013 OxOBCA write value OxO00A CRC 0x4A14 Slave Tx 01060B C4 00 0A4A 14 addr 0x01 funct 0x06 reg 3013 OxOBC4 stored value Ox000A CRC 0x4A14 Write Multiple Register Regs 3014 0x0BC5 3017 0xOBC8 This sample message turns on the slave s Timed DO s 1 200ms 2 400ms 3 600ms 4 800ms Master Tx 01100B C5 00 04 08 00 02 00 04 00 06 00 08 90 7B addr 0x01 funct 0x10 start reg 3014 OxOBC5 of reg 0x0004 byte count 0x08 DO 1 0x0002 DO 2 0x0004 DO 3 0x0006 DO 4 0x0008 CRC 0x907B Slave Tx 01 10 0B C5 00 04 D3 D3 addr 0x01 funct 0x10 start reg
9. wave signal typical of an inductive pick up on a turbine meter factory default setting 2 Logic level pulse signal This setting accepts a driven pulse that is switching between zero volts and a positive voltage The pulse voltage can be 0 5V up to 0 16V but should not exceed V 3 Open collector transistor or reed switch With this setting a 10K ohm pull up is provided on board so a dry contact signal can be used 4 Dry mechanical contact requiring de bounce This setting is the same as 3 above but with the addition of signal de bounce Most relay and mechanical switches need de bounce Table 1 below shows DIP Switch settings for the different pulse input signal types 1 5 S1 6 S1 7 Pulse Input Signal Type OFF OFF OFF Low level differential sine wave OFF ON OFF Logic level pulse signal ON ON OFF Open collector transistor or dry reed switch ON ON ON Dry mechanical contact requiring de bounce Table 1 G303 User s Guide 2010 01 28 RADIO POWER SAVE DIP switch S1 position 8 The G303 RIO hardware is designed to support powering down the radio between communication cycles in order to reduce power consumption However the current embedded firmware does not support this feature MODBUS SLAVE ADDRESS DIP switch S2 positions 1 8 The device address is set on the 8 position DIP switch S2 The address value is equal to the sum of the labeled values for the individual switches that are turned
10. 010 01 28 10 MODBUS Register Map Register 3001 3002 3003 3004 3005 3006 3007 3008 3009 3010 3011 3012 3013 3014 3015 3016 3017 Table 4 All register values are integers and the hex values are indicated by prefix Ox For example OxOFFF hex is the equivalent decimal value 4095 The register address is zero based and the register number starts at one This creates an offset of one between the register number and the register address For example register number 3001 Digital Input bits is addressed as OxOBB8 3000 decimal Each register is a 16 bit word Unimplemented bits are zero filled Data is transmitted using big Endian representation where the high byte is transmitted then the low byte The CRC value is the only value transmitted using little Endian representation where the low byte is transmitted then the high byte Register 3001 Digital Input bits A bit value of zero indicates the input is not active and a bit value of one indicates the input is active Digital Inputs 1 8 are indicated in the lower 8 bits of the register The upper 8 bits with asterisks are also Digital Inputs 1 8 but with minimum 30sec hold time in order to capture stretch short duration DI events Bit 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 Digital Input 8 7 6 5 4 3 2 1 81 71 1615 4 3 2 1 Table 5 Register 3002 3006 Analog Inputs The analog to
11. 2010 01 28 Introduction This guide covers the operation installation and configuration of the RIO industrial grade Remote I O Model G303 The RIO is an easy to use MODBUS Slave Remote I O module Since the RIO is designed for the simple task of reading inputs and driving outputs using common pre defined Modbus commands it requires no software configuration except for radio parameters see Radio Configuration section and can be polled from most any Modbus Master For wireless RIO models a compatible SS Radio Modem i e Model G306C Wireless Modem is used on the Master s serial port The RIO is a low power and environmentally tolerant device that provides reliable access to remote or hard to reach Digital amp Analog process signals for both monitoring and control and is suitable for solar powered outdoor sites Models are available for wired RS485 and RS232 or integrated wireless high performance FHSS Radio data communications Optional data port connection NOTE RPSMAF antenna connector or RS232 DB9M DIP switches and J14 are exposed in this image for example only p To meet Class Div 2 requirements the cover must be removed four screws to access Jumper J14 and DIP switches S1 amp S3 and they l should not be changed unless Vx o the area is known to be e SIG non hazardous 9 Di RS485 Data Port 7 Mic expansion port when e SIG using integrated radio N Y GND RS 485 Analog Inputs
12. 3014 OxOBC5 of regs written 0x0004 CRC 0xD3D3 G303 User s Guide 2010 01 28 13 PC Master Communication Connections Interconnect 1 For temporary short distance wired data communications between a PC and the G303 RIO i e for configuration of the RIO s radio or for bench testing set the RIO DIP switches for 4 wire RS485 and use a custom adapter cable as shown in Figure 7 on next page to connect the PC s RS232 serial port to the RIO s RS485 port Note This connection is not recommended for permanent installations 2 For an installation requiring wired RIO communications to an RS232 Master device PC RTU PLC etc there are two options If a single RIO is needed the G303 600 has RS232 port may be used However the G303 000 RS485 port only can be use along with the addition of an RS232 to RS485 converter at the Master Now the wired communications can be standard RS485 and support either single or multiple RIO units 3 For wireless RIO communications a compatible Wireless Modem must be used on the PC serial port The G306C Wireless Modem works with the most common wireless RIO models See Ordering Information at the end of this document to determine compatible models or contact G3 Technologies for assistance Wndows based DEMO HMI pkg The G3 VUE HMI software is available both for demo testing and to be used as a system HMI where graphic displays are not required and low cost is a priority It acts as a Modbus Ma
13. Hz 5KHz lt gt 0 10Hz 64 L RADIO POWERON PWR SAVE NOT USED gt 128 T e WARNING Do not change DIP Switch or Jumper settings unless the area is known to be non hazardous To access S1 S3 amp J14 remove the four screws on the cover and lift the cover off vertically Figure 6 Vx 24V OFF 12V J14 with shunt jumper The sensor excitation voltage Vx can be set to either 12Vdc nominal or 24Vdc or it can be turned off In the 12V setting Vx will vary with the input voltage V in the range of 10 5 to 16Vdc In the 24V setting the internal DC DC regulator will maintain Vx 24Vdc Without the shunt jumper the Vx supply is turned off reducing power consumption for cases where Vx is not needed Factory default is 12Vdc ANALOG INPUT TYPE DIP switch S1 positions 1 4 Each of the four analog inputs is selectable to accept either a 0 5V 1 5V or 0 20mA 4 20mA signal The default factory analog input setting is 0 20mA 4 20mA We suggest that unused unterminated analog inputs be set to 0 20mA 4 20mA This will bias the unterminated analog input at zero PULSE INPUT SIGNAL CONDITIONING DIP switch S1 position 5 7 The Pulse Input can be set to accept several types of pulse signals The primary choices are as follows refer to Table 1 below for appropriate DIP switch settings 1 Turbine meter with inductive pick up This setting accepts direct connection of a low level differential sine
14. Size Download new versions Read OCT MTS COM2 9600 8 N 7 FLOW NONE X09 008 Ver 5000 Figure 9 Com test Query Modem Step Two Open X CTU and establish communications with the radio in the G303 RIO 1 Double click the X CTU icon to open the utility 2 On the PC Settings tab opening screen select the desired Comm Port from the list 3 Verify that Baud Rate is set to match that of the RIO set on DIP Switch S3 most common is 9600 baud Parity None Data Bits 8 and Stop Bits 1 4 Click on the Test Query button to test communications between X CTU and the radio in the RIO A pop up shown below will indicate the query results If successful continue to next step Otherwise re check setup and settings described above and try again Communication with modem OK 9 009 Modem firmware version 5000 Step Three Read the radio s existing Parameter Settings and select new Hopping Channel RF Net Code 1 Select the Modem Configuration tab and then click on the Read button After a few seconds the blank screen will be filled in with a list of the current software parameter settings stored in the radio 2 Locate the line in the parameter display that reads 0 HP Hopping Channel It indicates that the Hopping Channel RF Net Code is set at 0 which is the default value 3 To change the RF Net Code click on the Hopping Channel line a
15. alog Input Description amp Wiring Diagram Each of the four analog inputs is DIP switch selectable for use with either a 0 5V 1 5V or 0 20mA 4 20mA signal In order to meet Class I Div 2 hazardous location requirements the cover must be removed in order to access the DIP switches To do so remove the four phillips head screws on the cover and lift the cover vertically The default factory analog input setting is 0 20mA 4 20mA We suggest that unused unterminated analog inputs should be set to 0 20mA 4 20mA This will bias the unterminated analog input at zero By placing jumper J14 the sensor excitation voltage Vx can be set to either 12Vdc nominal or 24Vdc In the 12V setting Vx will be approx the same as the input voltage V In the 24V setting the internal DC DC regulator will maintain Vx 24Vdc over the full 10 5 16Vdc input voltage range The load on each Vx terminal should not exceed 20mA In solar powered applications where power conservation is a concern there are practices that can help lower the power requirements Using 1 5V rather then 4 20mA sensors is generally recommended For sensor power set Vx selection jumper J14 for 12V if 24V is not required and set it for off if no sensor power is needed The internal Analog Input 5 AI5 monitors the power input supply voltage V 0 16V voltage range The analog to digital converter for all of the analog inputs is 12 bits providing a 0 4095 decimal count for zero to f
16. ance Performance Add timed DO register support Add pulse per minute PPM rate Add RTS support for FSK Modem push to talk PTT option Change baud rate to 600 1200 9600 19200 crystal frequency to 3 8MHz Beta release G303 RIO Hardware Revision History July 2009 2003 CSA Class Div 2 certified G303 only change is flanges on the metal cover to restrict access to the DIP Switches Original Release G303 User s Guide 2010 01 28 19
17. d and RS485 expansion port G303 500 RIO w FSK Modem for external VHF UHF analog radio support 600 baud G303 600 RIO w RS232 comm port DB9M DTE G306C 04 RF Modem 900MHz compatible w G303 040 G306C 08 RF Modem 2 4GHz compatible w G303 080 Starter Kits NEMA 4X packages and accessories antennas solar components amp etc are available from G3 Technologies Other models of Wireless I O and RF Modems are also available Please contact our office for additional information as well as for product pricing availability and support Warranty This product is covered by a one year limited warranty against defects in material and workmanship The full Warranty statement as well as Terms amp Conditions of Sale are available from the G3 Technologies web site Contact Information G3 Technologies Inc 2536 W 239th St Louisburg KS 66053 Ph 913 963 7300 Fax 913 964 3010 E mail sales g3ti com Web site www g3ti com G303 User s Guide 2010 01 28 18 G303 RIO Firmware Revision History The G303 firmware is factory loaded and requires no field revision Contact G3 Technologies for assistance The revision history below is listed latest to earliest Version 1 07 Version 1 06 Version 1 05 Version 1 04 Version 1 03 Version 1 02 Version 1 01 Version 1 00 2009 10 10 2006 2005 2004 07 08 2004 05 29 2004 03 14 2003 10 21 2003 08 05 Add fast DI sampling and 30sec DI pulse stretching Enhance Performance Enh
18. emale on units with integrated SS radio DB9M DTE on units with RS232 option in place of radio G303 User s Guide 2010 01 28 Input Power The RIO should be powered from an isolated source Solar and battery power sources are inherently isolated For line voltage connected AC DC power supplies verify that they have the proper secondary isolation To protect the power supply wiring a 2A Slow Blow fuse should be installed in the secondary AC circuit powering the unit The V supply voltage range for the RIO is 10 5 16Vdc The RIO is designed with very low power consumption making it suitable for solar powered applications It is also designed to be able to power down the radio as a power save feature but the firmware does not currently support this feature The following solar site calculations provide an example of the factors that effect the solar panel and battery sizing Because of the many factors that affect the sizing requirements for a solar installation please contact G3 Technologies for specifics We are happy to assist in determining the best configuration for your application Solar Site Example RIO w radio 10 sec poll rate V Supply amp Vx 12V nominal Two 2 Digital Inputs assumed active 5mA ea Two 2 1 5V Sensors 3mA ea 4 20mA sensors would be calculated at full scale 20mA Solar Array Size l oad avg 24hrs 12Vdc Average Sun hrs day Where load Avg Average Current Load 9 9 10sec 65mA RIO sta
19. etting 1A fuse Internal analog Al5 monitors V 0 16Vdc range accuracy 1 FS Jumper selected 12V or 24V self resetting 100mA fuse 1 Base unit 15mA 2 Each energized DO relay 12mA 3 Each active Digital Input 4mA 4 Optional low power SS radio Standby Rec 25mA Xmit 65mA 5 Optional 1Watt SS radio Standby RX 40mA TX 50 340mA 6 RS232 or FSK Modem 15mA Total power consumption is the sum of all the internal loads plus any external loads being supplied Power consumption is also affected by Poll Rate since current draw is significantly higher during the Transmit cycle Max rating is 600mA 12Vdc LEDs for CPU status TX RX 8 ea Dls 4 ea DOs and Power All power serial port and I O connections meet or exceed minimum standards for ESD EFT and Surge withstand per the international IEC 1000 4 standards FCC Part 15 ClassA CSA C US Class I Div 2 Groups A B C D Temp Code T3C 40 to 80 C 5 95 relative humidity non condensing All wire connections are pluggable screw terminals 0 2 spacing Recommended Screw Torque 4 5 Ib in 12 28 AWG To meet Class Div 2 requirements cover must be removed 4 ea phillips head screws to access DIP Switches S1 amp S3 Powder coated aluminum non rated 8 42L x 4 15W x 1 6H overall 19 oz 500g Panel mounting 7 76 x 2 4 rectangular pattern key hole 8 pan head screws recommended Optional mounting clip available for TS 35 DIN Rail mounting RPSMA f
20. fer to the Radio Module User Manual Version 5000 from Digi International for detailed instructions for Repeater configuration It is a free download from www digi com support documentation Also G3 Technologies can assist and in some cases may be able to supply pre set configuration files for Repeater and Repeater End Node configuration There are a number of other advanced functions that can be configured on these radios using the X CTU configuration utility but they generally require a more thorough understanding of the unit s function and should be done only by qualified personnel Digis User Manual has detailed information about the function and configuration of advanced radio features Contact G3 Technologies if additional assistance is needed G303 User s Guide 2010 01 28 17 Mounting Dimensions All dimensions are in inches Overall dimensions are 8 42 x 4 15 Mounting hole pattern dimensions are 7 76 x 2 40 8 Pan Head screws are recommended for panel mounting Optional clips for TS 35 DIN rail mounting PN 35 001 are available from G3 Technologies 0 33 7 76 0 33 En 2 BT 4 15 2 40 ar bOM A d 8 42 Figure 10 Ordering Information Part Number G303 000 RIO w RS485 comm only no radio G303 040 RIO w 900MHz 100mW SS radio 9600 baud and RS485 expansion port G303 080 RIO w 2 4GHz 50mW SS radio 9600 baud and RS485 expansion port G303 140 RIO w 900MHz 1W SS radio 9600 bau
21. ister decrements to zero the corresponding relay will de energize A timed DO can be set from 100mS up to 1 8 hrs with variation of 0 100mS As example if a value of 5 is written to register 3014 DO1 will be energized for 500mS The action of theTimed 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 corresponding DO relay will be energized regardless of the value in the Timed DO register G303 User s Guide 2010 01 28 12 MODBUS Communications The G303 RIO communicates using MODBUS RTU Slave protocol with 8N1 8 data bits no parity 1 stop bit data structure Data integrity checking uses 16 bit CRC that follows the CRC CCITT specification The following Modbus function codes are supported Function Code 03 0x03 Read Holding Registers Function Code 06 0x06 Write Single Register Function Code 16 0x10 Write Multiple Registers Table 7 Since Function Code 03 Read Holding Registers is used for reading register values in the RIO common Modbus definition would define these registers in the 40000 range i e to read register 3001 Digital Input bits from a RIO slave some Modbus masters would define it as register 43001 though only the 3001 value is transmitted to the slave If the Modbus master attempts to perform a function not supported the slave returns an Illegal Function exception response MODBUS Message Examples data values
22. le 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 in 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 written value of 1 up to 1 8 hours written value of FFFF hex 0 100mS In addition to pulsed DO or Jog functions for control this feature can also be used as a Communication Loss Timeout feature By periodically writing a time value to the Timed DO register that is greater than the time between writes the DO relay will remain energized If communications is interrupted then the Timed DO register will time out and de energize the corresponding DO relay indicating comm loss 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 the corresponding relay will be energized regardless of the value in the Timed DO register The relay contacts are UL rated for 10A at 30Vdc resistive 10A at 250Vac general use 1 4HP 120Vac 1 2HP 250Vac B300 and Q300 pilot duty Each relay provides 4000 volt contact to coil isolation for surge protection Digital Outputs Field Wiring Example using normally open contacts DO4 DO3 Internal Relay Contacts DO2 m p DO1 Figure 3 G303 User s Guide 2010 01 28 An
23. nd enter the value of your choice 0 6 IMPORTANT The radio s CS parameter listed under Serial Interfacing is factory set at the non default value of 1 for RS485 Enable Low Be sure CS remains set properly before proceeding to step 5 4 Click the Write button to load the new value into the radio A note at the bottom of the X CTU screen will indicate that the Write cycle was successful 5 Again click Read and verify that the new selected value reads back correctly This completes the configuration of a new Hopping Channel RF Net Code for the G303 RIO Note that X CTU allows you to Save and Load configuration parameter files on your PC G303 User s Guide 2010 01 28 16 Using X CTU for Radio configuration cont d Upgrading or changing Radio Firmware If it becomes necessary to upgrade or change the Firmware Version on the radio in the G303 RIO follow these instructions Refer to previous pages for setup of X CTU on the PC and using it to communicate with the RIO for radio configuration After reading the current configuration from the RIO s radio you will notice at the top edge of the display window on X CTU there are drop downs for selecting RF Modem Type Function Set and Firmware Version Select the desired Firmware as follows 1 Select the RF Modem Type X09 009 XStream 900MHz 100mW 9600 baud used in model G303 040 X24 009 XStream 2 4GHz 50mW 9600 baud
24. ndby 0 1 10sec 165mA RIO xmit 10mA DI wetting current 6mA sensor current 6mA Solar Regulator I cad Avg 88MA 0 088A Average Sun hrs day depends on the geographic location and time of year For this example we will use the Winter Average Sun hrs day for Boise ID 3 33 hrs day Solar Array Size 0 088A 24hrs 12Vdc 3 33 Sun hrs day Solar Array Size 7 61 Watts A standard 10W Solar Module could be a good choice Minimum Battery Size l sad avg 24hrs Days of Autonomy Temp Factor of Discharge Where I cad Avg 88MA 0 088A Days of Autonomy The number of days without sun that the load current is supplied solely by the battery Six to Eight days autonomy is common for 99 9 system availability Temp Factor Batteries are effected by temp A cold battery will store and supply less energy For this example we will use the Boise ID average January temp of 25 deg F 1 5 Temp Factor of Discharge The deeper the discharge the shorter the battery life The of Discharge should not be more then 80 Minimum amp hour Ahr Battery Size 0 088A 24hrs 8 days 1 5 Temp Factor 0 8 Discharge Minimum Battery Size 31 7 Ahr A common 33Ahr battery could be a good choice Grounding An important item to verify is the proper grounding of the equipment installation Properly grounded electrical equipment will be safer operate with less electrical noise and minimize the potential damage fr
25. needs to be considered However when reading pulse rates for slower pulses just the lower register can be used The lower register can also be used as a 60sec pulse stretcher when the Pulse Input is being used to detect short duration periodic events In this case a value greater then zero indicates that an active DI event has occurred within the last minute DIP switches can be set for minimum pulse event duration detection of 350uS or 8mS Register 3012 Code Version The code version number high byte contains the major version number and the low byte contains the minor version number For example if register 3012 contains 0x0105 it can be viewed as version 1 5 Register 3013 Digital Output bits latched Bits 1 4 in this register represent DO1 4 Writing a bit value of 1 turns on the output and writing a bit value of 0 turns off the output Writing a bit value to bits 5 16 has no effect Reading the register will return the output value for DO1 4 and all unimplemented output bits will return a value of zero The register value is initialized to zero on power up Bit Digital Output Table 6 Register 43014 3017 Timed Digital Outputs There is a Timed Digital Output register for each of the four DOs DO1 4 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 then when the reg
26. ngs 10 ea RF Channels hopping channels Use XCTU Config Utility see Radio Configuration section 8 ea DI1 8 Active low sink to power common non latching amp optional 30 sec hold Minimum active input detection 2mS Optical coupling for surge noise tolerance amp filtering 12V wetting voltage 5mA wetting current 4 ea DO1 4 Form C N O amp N C relay contacts UL rated at 10 Amps 30Vdc resistive and 240Vac general use Pilot Duty B300 amp Q300 4 ea Al1 4 0 5V 1 5V or 0 20mA 4 20mA Individually DIP switch selectable 250 ohm 0 1 3W wire wound resistor on board for mA input Input low pass RC filter lt 1000Hz A D conversion is 12 bit resolution Overall accuracy 0 25 FS typical accuracy 0 1 FS 25 C Over voltage tolerance 30Vdc Totalizer 16 bit hdwr 32 bit sftwr PPS amp PPM Rate Signal input is configurable for a variety of input types having different sensitivity and frequency response characteristics See Pulse Input section later in this document for details G303 User s Guide 2010 01 28 Power Input Voltage V Input Voltage Monitor Transducer Power Vx Typical Current draw 12Vdc Total power consumption Miscellaneous Diagnostics Surge protection Certifications Physical Operating Temperature Humidity Field Wiring Connections DIP Switches Enclosure Dimensions in Weight Mounting Antenna Connection RS232 Connection 10 5 to 16 Vdc self res
27. om power line surges or lightning strikes We recommend a common point or star grounding configuration where all of the equipment in a panel are directly connected to the common grounding point The common grounding point is then connected to an 8 ground rod or other suitable grounding system using 14 AWG or larger copper wire Check with local regulations for specific grounding requirements G303 User s Guide 2010 01 28 Digital Input Description amp Wiring Diagram The RIO has 8 Digital Inputs DI1 8 They are active low meaning that a DI input is driven shorted to power supply common when active typically by a dry contact These inputs can be driven by relay contacts switch contacts or open collector transistors The digital inputs are internally powered with a wetting voltage approximately equal to the power supply voltage V and a wetting current of 5mA and are optically coupled for transient protection and noise filtering Any pulse or change of state that lasts for more than 2mS will be detected In the Digital Input register 3001 the lower 8 bits indicate real time values for the 8 digital inputs active 1 inactive 0 and the upper 8 bits are a duplicate except that they hold any active DI for a minimum of 30 seconds This 30sec hold feature can be used as a stretched indication of short duration events NOTE For a single input signal providing a short duration pulse the Pulse Totalizer Rate Input can also be u
28. omplished by writing to timed Digital Output Low power Spread Spectrum Radio option 900MHz 100mW amp 2 4GHz 50mW models Indoor Urban Range w 2 1 dB dipole antenna Outdoor RF line of sight Range w 2 1 dB dipole antenna Outdoor RF line of sight Range w high gain antenna Receiver Sensitivity Transmit Power Output Baud Rate Radio Channels Radio Configuration 900MHZz up to 1500 450m 2 4GHz up to 600 180m 900MHZz up to 7 miles 11km 2 4GHz up to 3 miles 5km 900MHZz up to 20 miles 32km 2 4GHz up to 10 miles 16km 900MHz 110dBm 2 4GHz 107dBm 900MHz 100mW 2 4GHz 50mW 9600 or 19 2K baud dictated by SS Radio being used 7 ea RF Channels hopping channels Use XCTU Config Utility see Radio Configuration section 1 Watt Spread Spectrum Radio option 900MHz only Indoor Urban Range w 2 1 dB dipole antenna Outdoor RF line of sight Range w 2 1 dB dipole antenna Outdoor RF line of sight Range w high gain antenna Receiver Sensitivity Transmit Power Output Baud Rate Radio Channels Radio Configuration Discrete I O Digital Inputs Dl Digital Outputs DO Analog Inputs Al Pulse Totalizer Flow Rate Event Capture Input Up to 3000 900m at 9600 baud Up to 14 miles 22km at 9600 baud Up to 40 miles 64km at 9600 baud 110 dBm 1mW to 1Watt software configured 1200 9600 19 2K baud software configured must be configured to match DIP Switch baud rate setti
29. sed see Pulse Input section later in this document The pulse input provides Modbus registers for both the accumulated pulse total as well as pulse rate in pulses per second PPS and pulses per minute PPM An event providing an input pulse greater than either 0 35mS 350uS or 8mS in length DIP switch selected filtering will be detected and can be read either as a totalizer increment or as a non zero value in the rate registers The PPS and PPM rate registers will hold the non zero value for 1sec and 1min respectively effectively providing a pulse stretching one shot Also by using these registers multiple events occurring in rapid succession will be detected and recorded Digital Inputs Field Wiring Example RELAY CONTACT SWITCH CONTACT Internal Logic typical of 8 O C TRANSISTOR Figure 2 G303 User s Guide 2010 01 28 Digital Output Description amp Wiring Diagram The four digital outputs DO1 4 are relays with Form C contacts at the screw terminals They can be either latched or a timed pulse 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 The relays hold their state until the value in the register is changed The DO registers are set to 0 upon power up For timed pulse DOs each of the four DOs has its own 16 bit register A sing
30. ster polling the RIO units for data and displays the returned data It also includes diagnostic features like serial data string display and communication performance tracking G3 VUE is a free download from the G3 Technologies website www g3ti com The free version is full featured except that it only supports polling and data display for one Slave RIO unit An unlock code may be purchased from G3 Technologies for its full use Antenna and RF Considerations RF Range The RIO with integrated SS Radio operates in the ISM 900MHz or 2 4GHz frequency bands At these frequencies the RF signal is able to travel a considerable distance line of sight LOS but is significantly attenuated if not LOS At these higher frequencies the RF signal does not bend around obstacles like UHF VHF and other lower frequency RF signals Obstacles in the line of sight are generally the key consideration when evaluating the radio communications path For short distance of less than a few miles obstacles such as trees and buildings can often be overcome by raising the antenna or relocating the equipment The type of antenna and its gain rating are also key factors Use of RF Repeaters For longer distances or for situations where raising the antenna height becomes impractical one or more repeaters can be used to extend the range However when configuring even a single radio in a system to act as a repeater special configuration is required for all radios in the system
31. t way to determine radio system requirements before installing equipment See Radio Configuration section for details G303 User s Guide 2010 01 28 14 Radio Configuration using X CTU Config Utility The radios used in the G303 RIO are XStream low power or XTend high power RF modules from Digi International formerly MaxStream The RIO units are shipped with radio configuration settings suitable for most applications Selecting a Hopping Channel RF Net Code For typical applications the only software parameter that will need to be changed is the Hopping Channel and that only for certain unique situations The Hopping Channel default is 0 but can be set for any one of 7 0 6 different pre defined pseudo random hopping sequences used for the Frequency Hopping Spread Spectrum FHSS Only units on the same Hopping Channel will hear respond to each other Therefore in situations where multiple wireless networks need to co exist the Hopping Channel can be set at different values for each of the networks to provide isolation between them NOTE If using the RioLink Wireless Modem model G306C to communicate with Wireless I O units from G3 Technologies RIO RioExpress amp etc note that the Hopping Channel selection on the RioLink and on the Wireless I O must match in order for them to communicate with each other Installing X CTU Config Utility X CTU is a configuration utility provided by Digi International as a free do
32. tching between zero volts and a positive voltage not to exceed V Switching point is approx 2096 of V Frequency range is 0 1 5KHz symmetrical 3 Open collector NPN transistor or reed switch 81 5 on S1 6 on S1 7 off Single ended on board 10K ohm pull up to Vcc Switching point is approx 2096 of Vcc Frequency range is 0 1 5KHz summetrical 4 Dry mechanical contact 81 5 on S1 6 on S1 7 on Single ended on board 10K ohm pull up to Vcc wetting voltage Switching point is approx 20 of Vcc Contact de bounce 7mS with frequency range of 0 60Hz symmetrical Pulse Input Types amp Field Wiring Examples Ew OR OR Turbine Meter Logic level NPN Transistor Dry Metalic differential voltage pulse open collector Contact sine wave switch or relay etc See Table 1 for proper DIP Switch setting for each type Pulse Signal Input Figure 5 G303 User s Guide 2010 01 28 DIP Switch and Jumper Settings DIP Switch amp Jumper Settings factory default shown J zo y SELECT 4WIRE 2WIRE 8 O gt umper 4WIRE 2WIRE S J14 24V OFF 12V BAUD SELECT BIT 2 LY o OR Geo boo cm SEE CHART BITA Ms Shunt Jumper Positions Ee e 1 2 2 Alt 2518 CO Ll Al2 o sy c 0 20mA SLAVE Ts E Iw He Al 3 gt 4 w Cols Al4 ADORE gt 8 Es a PI PULLUP 1 255 16 D lo a DIFF SINEWAVE c2 BEGND SUM OF VALUES 35 Ie O PlFreq 10
33. ull scale inputs WARNING DIP switch and Jumper selections should not be changed unless the area is known to be non hazardous Analog Input Field Wiring Example Internal Logic Typical 3 wire Filter Voltage Output Sensor uc Typical 2 wire Filter 4 20mA Sensor amp etc Figure 4 G303 User s Guide 2010 01 28 Pulse Totalizer Flow Rate Event Capture Input Description amp Wiring Diagram The G303 RIO has one 1 specialized pulse input Associated Modbus registers are provided for pulse totalization pulses per second PPS rate and pulses per minute PPM rate This input is also useful for capturing a periodic event that generates a pulse as short as 0 35mS 350uS or with filtering that requires minimum pulse width of 8mS No reset function is provided for the totalizer or rate registers However since the Modbus registers reside in RAM volatile memory power on initializes them to zero Screw terminals are provided for and pulse signal DIP switch settings 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 S1 5 off S1 6 off S1 7 off Differential input w 20K ohm input impedance for AC sine wave input no DC component Input sensitivity is 80mV p p at 10 Hz and 2 0V p p at 2 5KHz 2 Logic level pulse signal S1 5 off 81 6 on S1 7 off Single ended swi
34. wnload from their website It can be used to make software configuration changes to the Radio Module contained in the RIO To download and install X CTU go to www digi com and do a search for X CTU It will open a page where you can select to download the X CTU Installer Follow on screen instructions Using X CTU to configure Hopping Channel RF Net Code Step One PC and G303 RIO Setup 1 The PC must have an available RS 232 serial port If USB is all that is available on the PC a USB to Serial Port adaptor can be used 2 XCTU must be properly installed on the PC see instructions above 3 Since the PC must communicate through the RS485 port on the RIO in order to configure the internal radio an adaptor cable must be used to connect between RS232 and RS485 See Figure 7 below for wiring between RS232 and RS485 and note that DIP Switch S3 must be set for 4 wire RS485 operation 3 Use a straight through DB 9 RS 232 cable if additional length is needed to connect between the PC serial port and the adaptor cable 4 Connect power 10 5 16Vdc to the G303 RIO Serial Data Comm Adapter Cable G303 to PC serial port available from G3 Technologies PN 05 010 6 G303 RIO 4 wire RS485 J13 DBadssml GND Pin 5 GND i Pin 2 RX TX dd Pin 3 TX i RS232 DTE pluggable to PC Laptop screw terminals Figure 7 G303 User s Guide 2010 01 28 15 Using X CTU for Radio Config cont d About PC Settings
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