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Data Delivery Devices VHF, UHF & ISM Wireless RTU RFScada 8ADI-9DO 4ADI-5DO User Manual
Data Delivery Devices VHF, UHF & ISM Wireless RTU RFScada 8ADI-9DO 4ADI-5DO User Manual
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RFScada 8ADI-9DO/4ADI-5DO Manual Ver 3.6 Copyright ©2005 Data Delivery Devices LLC Page - 81 – Bartlesville OK Tel 918-335-3318 FAX 918-398-9990 DAQFactory Configuration and Operation. DAQFactory is a very powerful process control, monitoring and acquisition program available form Azeotech (http://www.azeotech.com ). Running on a PC DAQFactory comes with built support for connecting to an RFScada device, so a complete application may be built very quickly without requiring complex details such as Modbus addresses, I/O maps etc. Due to the speed of application development and the built in drivers PC applications connected to an RFScada system are possible that would not have been economically feasible in the past. Data Delivery Devices LLC can provide the final application tailored to your requirements or the end user may write his own application using the developer version of DAQFactory. This gives an overview of configuring DAQFactory for operation with the RFScada units, plus accessing all of the RFScada status, inputs and outputs from within the DAQFactory developer version. For full details of DAQFactory programming and operation please refer to the DAQFactory manuals. Verifying Installation. When creating channels in DAQFactory ‘RFScada’ should appear in the available device list. If it does not then verify the two files RFScada.dll and RFScada.dds are in the main DAQFactory directory and restart DAQFactory. RFScada Configuration. The RFScada units all need to be correctly configured before operating with DAQFactory. There are several modes of operation with many complex routing combinations and settings possible. Typically a physically non-existent ‘virtual’ units registers will be overwritten by DAQFactory for outputs, and the RFScada master device will then route these overwritten registers to appropriate physical outputs. Use the RFScada configuration program to initially setup the RFScada devices for required routing. DAQFactory ‘Device Number’ and RFScada ‘Units’. In all DAQFactory access and commands the DAQFactory ‘device number’ corresponds to the RFScada physical (or virtual) unit, even if the unit is not connected to the PC serial port. This is because all RFScada units in a system continually exchange data via the radio network, with the ‘master’ unit, 0, accumulating input data from all the slave units then sending output data to all the slaves per the preset configuration. The ‘master’ RFScada unit, which has an assigned unit ID 0 is Device 0 in DAQFactory. The slave and any ‘virtual’ RFScada units will have ID’s of 1 to 31 which are also their Device
RFScada 8ADI-9DO/4ADI-5DO Manual Ver 3.6 Copyright ©2005 Data Delivery Devices LLC Page - 82 – Bartlesville OK Tel 918-335-3318 FAX 918-398-9990 numbers in DAQFactory. When DAQFactory accesses a Device number other than 0 it is actually reading or writing to the physical RFScada Unit 0 (master) which is connected to the PC’s serial port; RFScada Unit 0 will then read or write data via radio to the requested RFScada unit. All of this reading, writing, storing and forwarding occurs inside the RFScada Unit 0, and is completely transparent to the user and DAQFactory. For example, to access Unit 7, even though it is not physically connected to the PC (and it may be many miles away) in the DAQFactory channel setup assign the Device to 7. Physical Interface. The physical serial port connection from the PC running DAQFactory must be made to the RFScada device that is configured as the master, as it is the only device in an RFScada network with access to all of the RFScada network registers. The serial port connection may either be RS-232 or RS-485 (2 wire hardware automatic). All serial port parameters except the COM port are assigned automatically. DAQFactory Serial Port Selection. Before any DAQFactory access to the RFScada network is possible the COM port must be selected from within DAQFactory. A DAQFactory ‘channel command’ may be used to do this. First create a DAQFactory channel with the following properties, Device Type: RFScada; Device Number: 0; I/O Type: Command. Now when this channel is set to a value from within DAQFactory the value will become the serial port used for RFScada access. So simply assign a value of 1 to 16 to set the connected COM port. Once set the COM port is typically never changed, so it may easily be set once in the initial startup sequence. DAQFactory Serial Port Status. There are many possible serial port errors that could occur during communication between the PC running DAQFactory and the RFScada units, for example the user could attempt to select a non existent serial port or the serial cable could be unplugged. The status of serial port communications may be monitored from within DAQFactory and of course it may be used to initiate alarms and warnings. To access the serial port status set up a channel as Device Type: RFScada; Device Number: 0; I/O Type: Special; Channel: 1. Reading the channel will return the serial port state, with the following meanings: 0 Correct operation 1 to 4 Failed to initialize 5 – 9 Internal initialization errors 10 - 12 Failed to read correctly 13 to 16 Failed to write correctly RFScada Radio Network Status. If there are multiple physical RFScada units in the system then the RFScada units will continually communicate amongst themselves via the built in radios. The status of this radio network may be monitored from DAQFactory, and of course it may be used to initiate alarms and warnings. To access the RFScada radio network status set up a channel as Device Type: RFScada; Device Number: 0; I/O Type: Special; Channel: 2. Reading the channel will return the radio network status, with the following meanings. 0 Correct operation, every unit is communicating correctly.
RFScada 8ADI-9DO/4ADI-5DO Manual Ver 3.6 Copyright ©2005 Data Delivery Devices LLC Page - 83 – Bartlesville OK Tel 918-335-3318 FAX 918-398-9990 1 Some, but not all RFScada ‘slave’ units are responding to radio signals from the RFScada ‘master’ unit. 2 None of the RFScada ‘slave’ units are responding to radio signals from the RFScada ‘master’ unit. If the radio network status is 1 it is possible to find out which units are not operating correctly, refer to the RFScada individual network status. RFScada Individual Network Status. This returns the operational status of an individual RFScada unit. To access a units status set up a channel as Device Type: RFScada; Device Number: The units ID, 0 to 31; I/O Type: Special; Channel: 0. Reading the channel will return units radio network status. 0 means the unit is responding correctly, and 1 indicates that there is no response from the unit. Typically this status would only be read after an error was reported from reading the RFScada Radio Network Status, since it is much easier to read a single summary status than poll each individually. RFScada Software Version. The software version installed in the RFScada master unit may be read. To access the RFScada software version set up a channel as Device Type: RFScada; Device Number: 0; I/O Type: Special; Channel: 3. Reading the channel will return the software version as a number, e.g. 24 means software version 2.4 Local and Remote Analog Inputs. Analog inputs from every RFScada unit in a system may be read using the ‘A to D’ read function. To read an input set up a channel with Device Type: RFScada; Device Number: The units ID, 0 to 31; I/O Type: A to D; Channel: the units channel, 1 to 8. Reading the channel will return the analog input as a number from 0 to 1023, which corresponds to 0 - 20mA. Local and Remote Digital Inputs. Digital inputs from every RFScada unit in a system may be read using the ‘Dig In’ read function. To read an input set up a channel with Device Type: RFScada; Device Number: The units ID, 0 to 31; I/O Type: Dig In; Channel: the units channel, 1 to 8. Reading the channel will return the digital input as a number, either 0 for the input open circuit or 1 if the input is shorted. Local and Remote Analog Outputs. Analog outputs on every RFScada unit in a system may be written to by ‘overriding’ analog inputs that are then routed by the RFScada master unit to the desired analog output(s). (refer to the rest of this manual for a full explanation). Typically a non-existent ‘virtual’ units analog input is over written, and this is then routed wherever it is desired. To do this set up a channel that will use the ‘D to A’ write function. Use Device Type: RFScada; Device Number: The units ID, 0 to 31; I/O Type: D to A; Channel: the units channel, 1 to 8. Write to the channel a value from 0 to 1023, which corresponds to 0 - 20mA. Local and Remote Digital Outputs. Digital outputs on every RFScada unit in a system may be written to by ‘overriding’ digital inputs that are then routed by the RFScada master unit to the desired digital output(s). (refer to the rest of this manual for a full explanation). Typically a non-existent ‘virtual’ units digital input is over written, and this is then routed wherever it is desired. To do this set up a channel that will use the ‘Dig Out’ write function. Use Device Type: RFScada; Device Number: The
RFScada 8ADI-9DO/4ADI-5DO Manual Ver 3.6 Copyright ©2005 Data Delivery Devices LLC Page - 84 – Bartlesville OK Tel 918-335-3318 FAX 918-398-9990 units ID, 0 to 31; I/O Type: Dig Out; Channel: the units channel, 1 to 8. Write to the channel either a 1 (relay active, normally open contacts closed) or 0 (relay inactive, normally open contacts open). Cautions when Writing to Outputs. The RFScada Units are designed for operation in many diverse applications, and may control devices such as motors and pumps. It is possible during operation that the PC could fail, it may lose power or the serial connection between the PC and the RFScada Unit is lost for some reason. If this occurs it is important that the RFScada sets all of its outputs to the default ‘off’ state, (Analog outputs at 0 mA, all digital output relays off) to prevent any possible hazards or equipment damage. For this reason the RFScada Unit has a user programmable ‘Modbus Override Time’ value that needs to be set appropriately for the application (the default is 10 seconds). If a Modbus write to ‘overwritten’ registers does not occur within this time all overwritten registers on that unit will revert to the default state. So, in the DAQFactory application any output writes will need to be repeated by DAQFactory within the ‘Modbus Override Time’ to prevent written values reverting to default values. Just writing to a single output, either analog or digital, on a unit will reset that units timeout and all overwritten values on that unit will remain without requiring any other writes, since the timeout is for the unit as a whole and not for individual registers. A simple DAQFactory ‘Sequence’ that keeps writing more frequently than the Modbus override time to any register on any overwritten Unit will allow correct operation.
RFScada 8ADI-9DO/4ADI-5DO Manual Ver 3.6 Copyright ©2005 Data Delivery Devices LLC Page - 85 – Bartlesville OK Tel 918-335-3318 FAX 918-398-9990
RFScada 8ADI-9DO/4ADI-5DO Manual Ver 3.6 Copyright ©2005 Data Delivery Devices LLC Page - 87 – Bartlesville OK Tel 918-335-3318 FAX 918-398-9990 Modbus Configuration, Control and Monitoring. When the RFScada units are shipped they will already be configured for the final application, and no further programming, configuration or adjustments are required. Each unit stores its own settings inside non volatile memory where they will remain until the unit is reconfigured. Connection to power is not required to maintain these settings, there are no batteries or similar volatile devices required for storage. It may, however be necessary to change settings in the field if additional units are added to the system or changes in the configured settings are desired. It may also be desirable to monitor and possibly control conditions at various units using a computer. The RFScada units have this capability built in, via an industry standard protocol called Modbus, and by using a standard PC with suitable software virtually every input, output and configuration setting may be monitored or changed in the field by the user. It is also possible to permanently store new configuration settings in each unit. PC software is available from Data Delivery Devices LLC that allows units to be reconfigured in the field. The software also has basic monitoring and control capability, to allow the user to monitor or make simple control adjustments in the field, primarily intended for testing and demonstration. The complete Modbus map is also included here, so users may also connect to the RFScada devices using their own software via applications such as DAQFactory, LabView, Wonderware, Visual Basic etc. Physical Interface. The RFScada devices have two types of interface supplied as standard, called RS-232 and RS-485. Each interface has its own physical connector, with the RS-232 connector being a 4 pin Molex type socket on the lower right hand side of the board marked J15, and the RS-485 connecter is a three pin terminal block marked J16. Only one interface may be used at a time, and a 2 pin jumper, located by the RS-485 terminal block and marked J1, allows the user to select either RS-232 or RS- 485 operation. Install the jumper block for RS-485 operation, and remove it for RS-232 operation. Standard PC’s have an RS-232 serial port (typically a 9 pin male connector, occasionally a male 25 pin on the rear of the PC) which connects via a suitable cable to J15 on the RFScada board. A suitable cable is available from Data Delivery Devices LLC for connection to a PC’s RS-232 port, or use the following table for connections if constructing you own cable. PC RS-232 to RFScada Interface Connections Signal 9 Pin PC Serial Port 25 Pin PC Serial Port RFScada Received Data to PC Pin 2 Pin 3 J15 Pin 1 Transmit Data from PC Pin 3 Pin 2 J15 Pin 2 Ground Pin 5 Pin 7 J15 Pin 3 Shield Ground Shield Shield J15 Pin 4 For many industrial environments or locations which require long cable runs a standard called RS-485 is often used instead of RS-232, as it is far less prone to interference and many devices may be connected in parallel to a single interface cable. Low cost converters and other interface devices, such as electrical isolators, are available to allow a PC’s standard RS-232 serial port to convert RS- 232 data to the RS-485 standard. There are several versions of RS-485 available, the RFScada units conform to the most popular, called 2 wire since just two wires plus ground are required for interconnection. The following table lists the connections. RS-485 to RFScada Interface Connections
RFScada 8ADI-9DO/4ADI-5DO Manual Ver 3.6 Copyright ©2005 Data Delivery Devices LLC Page - 88 – Bartlesville OK Tel 918-335-3318 FAX 918-398-9990 Signal Connection Ground J16 Pin 3 A (transmit & receive) J16 Pin 1 B (transmit & receive) J16 Pin 2 RS-485 networks often use a terminator resistor, value 120 Ohm at either end of a transmission line. The RFScada units do not have this resistor on the main board, to allow it to be connected at any point. If the RFScada unit is the last device on the RS-485 network a 120 Ohm resistor may be connected between the A & B connections. Additionally surge arrestors may be installed on the 8ADI-9DO devices as shown if very long cable runs are used. The 4ADI-5DO board already has surge arrestors on the printed circuit board. As a final precaution when using extreme cable lengths a 100 Ohm resistor is sometimes installed in series with the shield between devices. If a large ground Voltage difference appears between the two sites the resistor prevents heavy currents flowing in the shield between locations. Software Interface. Suitable software is required on a PC to communicate with the RFScada devices. Software may be downloaded from the Data Delivery Devices website at no charge to provide configuration and basic monitoring of the units; this software is actually communicating with the RFScada devices via Modbus, using the following commands and Modbus ‘map’. It may be a useful starting point before attempting to connect using custom Modbus software; the Data Delivery Devices software may be used to verify hardware cables and connections first. When using Modbus to access the RFScada devices care must be taken as it is possible to activate outputs, completely alter the operation of individual units, the complete system and even render units inoperable until re-programmed for the desired operation. If the units are remote, for example being accessed via a Modem, it is possible to write values that effectively disable remote Modbus access. It is recommended that any changes be thoroughly tested with all external circuitry disconnected to verify correct operation before final connection. Remember to write changes to non volatile memory so they will remain after power is cycled to the device. The connection data rate is fixed at 9600 baud, no parity with one stop bit. The units will respond to three Modbus commands, command 3 (0x03 hex) which allows the user to read one or more registers at once, command 6 (0x06 hex) to write to a single register and command 16 (0x10 hex) which allows one or more registers to be written at once. Nearly all of the registers may be written to, with the exception of a few, such as the software version installed (register 609) which can only be read with command 3. To allow easy ‘block writes’ of register areas that may contain a read only register no errors will be reported via Modbus for attempted writes to read-only registers; they will simply not be written. It is important to understand the method of communication between RFScada units, as although all registers are available in every unit only a few are updated in ‘slaves’, whereas all registers are updated at the ‘Master’ unit, designated 0. To determine the type of unit read register 608, if it is zero this unit is the RFScada system ‘master’ and all registers are accessible. Under CAUTION
RFScada 8ADI-9DO/4ADI-5DO Manual Ver 3.6 Copyright ©2005 Data Delivery Devices LLC Page - 89 – Bartlesville OK Tel 918-335-3318 FAX 918-398-9990 normal circumstances Modbus access and control would be at unit 0, allowing full access to the system. Access at slaves is primarily intended for testing, to change local settings, such as a timeout value, or to override and ‘force’ local inputs via Modbus. In the following descriptions it is assumed that the Modbus connection is made to the master unit, 0. When connected via Modbus to a slave unit (i.e. the units id is 1 to 31) the only registers that have significance are the 10 related to that units id (for example 170 to 179 for unit 17, 30 to 39 for unit 3 etc), registers 608 to 614 and register 3318. Register Descriptions: The first 320 registers supply present readings and status for the units, with each unit having 10 registers. The first is the state of the 8 digital input switches, with a zero bit indicating an input switch is open. Bit 8, (which cannot be overwritten via Modbus, see explanation later) indicates if this unit is correctly communicating with the system master unit. The next 8 registers correspond to the user analog inputs, each being a 10 bit resolution input, with 20mA being a full scale reading of 1023. 0 corresponds to 0.0 mA, so it is possible to tell if a 4-20mA loop device is indicating minimum output or if the loop has been broken. The last register is the analog measurement of the DC voltage on the RFScada board, and may be used for general indication or for early warning of failing power, for example from a solar power supply. It is typically around 18 Volts DC when the unit is operating at 115 VAC, or about 1 Volt below the DC input Voltage if operating from an external DC power supply. Approximately 51 Volts DC is the full scale input for this reading, so values about 340 -380 are normal when operating on 115 VAC line input. Any of these 320 registers may be forced or ‘overridden’ via Modbus, to override local or remote conditions. Outputs on all units that rely on ‘Modbus overridden’ input registers as their signal ‘source’ will now output signals using these ‘Modbus overwritten’ values as sources. The RFScada ‘real’ values, taken from external sensors and switches for that relevant unit, will be blocked while overwritten via Modbus. All input registers for an overridden unit will be locked, so even if just the digital inputs on unit 12 are Modbus overridden all of unit 12’s registers are held at the present state. The Modbus overridden values will remain current until Modbus write commands for that particular units registers have not occurred for the time specified in the ‘Modbus override time’ register, 613. Once the registers have not been overwritten for that time the registers will automatically revert to sourcing signals from system read inputs, such as analog inputs and switches. This allows great flexibility, as any input on any unit may effectively be overridden via Modbus for testing or control purposes. Once Modbus overrides stop the unit will revert to normal operation. Only registers associated with ‘Modbus overridden’ ones are affected, and all other operations, including control, communications, monitoring and Modbus activity continue to occur normally. For applications that require some outputs to be driven only from Modbus simply configure those outputs to be driven from an unused unit ID, then they will only be updated from Modbus. The next 128 registers, from 320 to 447, control configuration for all the relay signal sources. These registers are similar to one another, and just differ by the relay, the unit and input bit that they refer to. Each relay is individually controlled by a digital input (or the Modbus register corresponding to that input). For example, register 368 configures relay 1 and 2 on unit 12. The least significant byte controls the signal source for relay 1, and the most significant byte relay 2. In each byte the most significant 5 bits are the source unit ID for the relay signal, and the least significant 3 bits are the digital input bit. So, in this case if the lower byte was 11011010 Binary (218 decimal or 0xDA hex) relay 1 in unit 12 would be driven by digital input 3 on unit 27. If the upper byte was 01100111 Binary (103 decimal or 0x67 hex) relay 2 in unit 12 would be driven by digital input 8 on unit 12 (its own unit). Each relay output may be sourced from any digital input, so it is possible to drive multiple relays on multiple units from the same digital input. The next 128 registers, from 448 to 575, control configuration for all the analog output signal sources. These registers are similar to one another, and just differ by the analog output, the unit and analog input channel that they refer to. Each analog output is individually controlled by an analog input (or the Modbus register corresponding to that input). For example, register 491 configures analog outputs 7 and 8 on unit 10. The least significant byte controls the signal source for analog output 7, and the most significant byte analog output 8. In each byte the most significant 5 bits are the
RFScada 8ADI-9DO/4ADI-5DO Manual Ver 3.6 Copyright ©2005 Data Delivery Devices LLC Page - 90 – Bartlesville OK Tel 918-335-3318 FAX 918-398-9990 source unit ID for the analog signal, and the least significant 3 bits are the analog input channel. So, in this case if the lower byte was 11011010 Binary (218 decimal or 0xDA hex) analog output 7 in unit 10 would be driven by analog input 3 on unit 27. If the upper byte was 01100111 Binary (103 decimal or 0x67 hex) analog output 8 in unit 10 would be driven by analog input 8 on unit 12. Every analog output may be sourced from any input, so it is possible to driven multiple (or all) analog outputs from the same analog input. The 32 registers from 576 to 607 specify if each unit is enabled. Register 576, for the system master (unit 0), must always be enabled, as it control communications between all units. If a non existent unit is enabled here the system will not operate, and indicate a ‘network’ error status. Register 608 is the ID of this device. If the ID is zero this unit will be the system master, be responsible for routing all signals between units, will have virtually all of the configuration settings for the system and will control communications between all units. One unit in a system must be the master, and there must only be one master in a system. If the ID is 1 to 31 this unit is a ‘slave’ unit, and just a few Modbus registers will have significance. Every slave must have a unique ID for correct operation, allowing a total of 32 units (one master plus 1 to 31 slaves) to be in one system. Slaves do not require sequential ID’s, and slaves may effectively be disabled by ‘un-enabling’ them in the masters configuration. The ‘receive data’ LED will flash rapidly on a disabled slave that monitors network traffic, but since it is never addressed it will never respond and will not transmit. Register 609 contains an image of the output relays on this unit. It is read only. Register 610 indicates the current network state, again it is read only. If it is zero the network is operating correctly and all configured units are communicating correctly; the ‘system status’ LED and relay on this and all other units will be on continuously. If this register contains 1 then this unit (if not the master) and the master unit are communicating and operating correctly, but at least one unit somewhere on the network is not communicating or operating correctly. On this and all other units that are operating the ‘system status’ LED and relay will slowly be toggling on and off, indicating an error somewhere in the system. Bit 8 in Modbus registers 0 to 320 and Modbus registers 577 to 607 may be compared to identify the exact enabled unit (or units) that are not responding. If register 608 contains 2 then this unit is not communicating with any other unit, and the ‘system status’ LED and relay will be off. Register 611 contains the user Modbus address for this device. It may be anything from 1 to 98 or 100 to 255 (default is 0, or off). Note that the RFScada units will also always respond to address 99 (0x63 Hex), so even if the Modbus address is zero or has accidentally been changed and subsequently lost the unit may still be accessed using address 99. The users Modbus ‘silent time’ (register 614) will also be ignored when accessed using address 99, see register 614 for details. Unless multiple RFScada devices are on the same Modbus network or special silent times are required it is suggested that the ‘always enabled’ address of 99 be used. Register 612 contains the default ‘loss of communications’ timeout value. For slaves, if valid radio communications are not received by this unit within this time frame the unit will change state to indicate ‘lost communications’. All outputs will change to default settings (i.e. off) and the ‘system status’ LED and relay will turn off. If this unit is the master this register contains the maximum time without receiving valid communications from every unit before changing state to ‘network error’; where the master unit and at least one slave unit are communicating and operating correctly, but at least one unit somewhere on the network is not communicating or operating correctly. On this and all other units that are still operating all outputs will change to default settings (i.e. off), the ‘system status’ LED and relay will slowly be toggling on and off, indicating an error somewhere in the system. The register time is in seconds, with the default set at 10, which is suitable for most systems with a few units and good communications. If many units are in a system this time may need to be extended to prevent network errors, for example caused by power being briefly interrupted on a single unit. Register 613 contains the time in seconds before reverting to normal operation after Modbus ‘override’ writes. If a register is written again via Modbus within this time period it will contain the latest ‘Modbus overridden’ value; if the timer expires the register will revert to normal, being updated by the RFScada inputs. Each time a write occurs to the relevant units registers its timer is restarted. See the section on registers 0 to 319 for further details.