H Unit Input/Output Manual 4 INPUTS 4 OUTPUTS RS485
Table of Contents Safety Rules...Inside Front Cover. Introduction...IFC 2. Communications...IFC 2.2 Baud Rate...IFC 2.3 Modbus Address... 2.4 Speed of Response... 2.5 Communications Failure... 3. Programming... 3.2 Communications Settings... 3.3 HUIO Configuration... 3.4 Setting Up the Inputs... 2 3.5 Setting Up the Outputs... 2 4. Input Specifications... 2 5. Output Specifications... 2 6. Power and Communications Connections... 2 7. Quick Setup... 3 8. Diagnostic Monitor... 4. INTRODUCTION The HUIO module is designed to connect to an H- panel (ONLY) and expand it s input and output capability. Each HUIO module has four (4) inputs and four (4) outputs. Up to four (4) modules can be attached to the H-panel to give a total of 6 additional inputs and 6 additional outputs. The state of the output relays can be seen on the PCB Led s -4. The additional Input/Output will appear to be a continuation of the existing Input/Output and will adopt all of it s properties such as channel naming, alarms, ILC visibility etc. The HUIO will connect to an H-panel via the simple 3-wire RS485 interface along with other peripherals such as HTS Transfer Switches, Remote Annunciators and Remote Relay panels. Because we are using RS485, the HUIO can be located up to 4000 feet away from the H-panel (depending on site and configuration). 2. COMMUNICATIONS The HUIO will connect onto the RS485 bus as a Modbus slave, along with any optional HTS units and remote annunciators/remote relay boards. 2.2 BAUD RATE The following baud rates are available - 4800, 9600, 38400, 57600. The baud rate for the RS485 port is set on the H-panel. At power up, the HUIO module will automatically search for the correct baud rate. If no good communications are received within three seconds, the HUIO will change it s baud rate on a cyclical basis. The baud rate search starts at 4800 baud. Once good communications are established, the baud rate will be held for two time-out periods even if the communications go bad. This is to prevent minor noise from causing the baud rate to cycle. Similarly outputs are disabled after one or two timeout periods depending if communications were ever established. The baud rate does not affect the speed of response (see section "Speed of Response").
2.3 MODBUS ADDRESS Each HUIO has base Modbus address of 230 plus a unique address which is set by two dip switches on the module (see Table ), giving a total of four possible options 230-233. The H-panel has to be programmed via Genlink (NOT THE FRONT PANEL) as to which modules are connected (which addresses are in service), i.e. it is not plug and play. The reason for this is that the H-panel would need to continually search for each unit, and each unit would be adjusting it s baud rate every three seconds. With the combination of time-outs and slow loop times, the bus would become sluggish, the baud rate continually changing, and we may never achieve a connection. Input and output designation is fixed by module address: Table ADDRESS SW SW2 230 0 0 Contains inputs 2-5 and outputs 7-20 23 0 Contains inputs 6-9 and outputs 2-24 232 0 Contains inputs 20-23 and outputs 25-28 233 Contains inputs 24-27 and outputs 29-32 2.4 SPEED OF RESPONSE HUIO s are serviced cyclically with two messages (read and write) sent to each connected HUIO in turn. The message length is very small so the speed of response is not affected by the baud rate. For example four units require eight messages. Each message is separated from the next by 300ms so each HUIO requires 600ms to be serviced. This results in a response time roughly equal to: 600ms * number of HUIO s Thus the worst case response time after the auto baud rate algorithm has established a connection is: 600ms * 4 = 2.4 seconds Any time critical Input/Output should be programmed to be on the original H-panel inputs and outputs as they have an almost instantaneous response. 2.5 COMMUNICATIONS FAILURE In the event that communications to a HUIO fail, a warning will be posted on the front of the H- panel. The warning WILL NOT SHUT DOWN THE GENERATOR. The HUIO inputs will be set to a known condition (0 or OFF ) and the outputs will turn themselves off. This process will take between.5 7.2 seconds. For example if there are four HUIO s the H-panel will only access any one at 2.4 second intervals at which time it will send both a read and a write message. The H-panel needs to see five missed messages before it confirms a failure, so it will take up to three intervals to make six message attempts, or, 7.2 seconds (3* 2.4 seconds). START Figure Communications Failure First read & write message to HUIO Second read & write message to HUIO 2.4s 2.4s 2.4s Third read & write message to HUIO 3. PROGRAMMING Genlink needs to be used to program the functions of the individual channels such as alarms, alarm properties, channel naming etc.. It is too complex to be done from the front panel. 3.2 COMMUNICATIONS SETTINGS Using Genlink, go to the communication port configuration page and set the RS485 port to be a Modbus master. Choose one of the four required baud rates (4800, 9600, 38400, 57600). If an old style remote annunciator is fitted the communications must be set at 4800 baud, no parity and two stop bits. Cycle the power to the H-panel for these settings to take effect. 3.3 HUIO CONFIGURATION The next act of programming is to tell the H-panel that a HUIO is to be connected (it s not plug and play, if a unit fails we need to know it s supposed to be there so we can post a warning if it s not). Set the dip switches on the HUIO(s) to give them a unique Modbus address (see Table ). If only one unit is to be connected we suggest leaving both switches in the OFF position to designate the unit as #. Next go to the HUIO configuration page and use the check boxes to select each of the HUIO s that are to be connected and apply the change. If the unit is not physically connected and communicating, a warning will be displayed on the front of the H-panel.
If a HUIO is not selected to be connected, then it s inputs and outputs will be ignored by the program EVEN IF IT IS PHYSICALLY CONNECTED. 3.4 SETTING UP THE INPUTS The new Inputs are numbered 2-27 in groups of four per HUIO module, for example, inputs 6-9 would always be on unit #2. The inputs appear on the digital input channel configuration screen just like any other input. Their status is also displayed on the input diagnostic screen in Genlink. Inputs can be given names and can be inverted, delayed, used to generate an alarm/warning and used to trigger an event. Refer to the Genlink help screen for this page if assistance is needed. A new direct output mapping method allows all of the new HUIO (only) inputs to be mapped directly to their own HUIO outputs. Alternatively, any alarm or warning generated by a HUIO input can be mapped to the HUIO output. Refer to section "Setting Up the Outputs" for examples. The new inputs are also available for use by the ILC programming tool supplied separately by the manufacturer. This allows the inputs to be logically combined just like a PLC to drive outputs or to trigger internal functions. 3.5 SETTING UP THE OUTPUTS The new Outputs are numbered 7-32 in groups of four per HUIO module, for example, outputs 2-24 would always be on unit #2. The output status appears on the digital output diagnostic screen in Genlink. The outputs are programmed by mapping them either to an output function (just like the standard outputs on the H-panel). Consult the Genlink help screen for the output function configuration page if assistance is needed. Alternatively the new HUIO outputs (ONLY) can be programmed via a new direct output mapping method. This allows any HUIO input to be either, directly mapped to it s same numbered output, or it allows an alarm/warning generated by that input to be mapped to an output. Here are some examples: HUIO #, input is directly mapped to HUIO # output. The state of the input is directly reflected by the output. However the signal can be programmed to be inverted via the input active level setting in Genlink. HUIO #2, input 3 is set as a warning and mapped to HUIO #2, output 3. When input 3 becomes active, a warning is generated. This warning activates output 3. Direct mapping is set up via radio buttons on the digital input channel configuration screen. These radio buttons only appear for HUIO inputs and not the regular inputs. The buttons are labeled as shown: Map Direct Map Alarm/Warning No Mapping The new outputs are available for use by the ILC programming tool supplied separately by the manufacturer. This allows the inputs to be logically combined just like a PLC to drive outputs or to trigger internal functions. 4. INPUT SPECIFICATIONS Each input is made active via a contact closure to ground. Two pins per input are provided for this purpose, one pin is grounded and the other is pulled up to 5V via a 4700 Ohm resistor. A volt free contact such as a relay or open collector transistor can be used to ground the input. The required current carrying capacity is in the region of ma. See Figure 2 for connection detail to J2. 5. OUTPUT SPECIFICATIONS Each output is made up of a pair of normally open relay contacts which close when the output is activated. The relay contacts are form A rated at 30 VDC and up to 5.0A each. NO AC CONNECTIONS SHOULD BE MADE TO THESE RELAYS. See Figure 2 for connection details to J5. The state of the output relays can be seen on Led s -4. 6. POWER AND COMMUNICATIONS CONNECTIONS Power is provided via a two-way Klippon style connector (J) which would normally be connected to the generator battery. Requirements are 6-30Vdc at 500 ma. The RS485 connection is made via a three-way Klippon style connector (J6). Wiring between units should be made using a twisted pair shielded cable such as Belden #9464. The shield should be connected AT BOTH ENDS as it acts as a common ground between the isolated ports. The RS485 network starts at the H-panel and can be daisy chained to various peripherals such as remote annunciators, remote relay panels, HTS switches and HUIO s. There should be only two terminating resistors in the whole network, one being fixed and in the H-panel. So, when fitting HUIO s the terminating jumper should be in the inactive position (on pins 2 and 3) when: 2
Figure 2 HUIO Outline INPUT GROUND FOR INPUT INPUT 2 GROUND FOR INPUT 2 INPUT 3 GROUND FOR INPUT 3 J3 J4 Modbus Address On 2 Jmp 2 3 J6 3 RS485+ 2 RS485 SCREEN RS485- INPUT 4 GROUND FOR INPUT 4 POWER + (2V) POWER - (GND) J2 J 8 2 Led Led 2 Led 3 Led 4 J5 8 OUTPUT 4 OUTPUT 4 OUTPUT 3 OUTPUT 3 OUTPUT 2 OUTPUT 2 OUTPUT OUTPUT NOTE: ) Power is nominally 2V but can be 6-30 VDC. 2) The RS485 screen should be connected at both ends. 3) JMP is the RS485 terminating resistor and should normally be fitted across Pins 2 and 3. (See manual for details.) 4) J4 is for the connection of a PC based diagnostic monitor. 5) J3 is reserved for the manufacturer s programming purposes. A. There is a remote annunciator on the network (which has a fixed terminator). B. There is an HTS on the network (which has a fixed terminator). C. There is a remote relay panel on the network which has a terminating resistor selected. The terminating jumper should be in the active position (on pins and 2) when: A. It is the only peripheral. B. It is at the far end of a bus which ONLY has other HUIO s on it. C. It is at the far end of a bus which ONLY has an un-terminated remote relay panel on it. Finally, don t worry too much about this termination business. It is unlikely to have any effect unless you are running at maximum bus length and very high speed (such as 57.6k baud). You will not damage the equipment if you terminate incorrectly. 7. QUICK SETUP. Set the Modbus address on the dip switch (e.g. off, off -for HUIO #). 2. Connect up the RS485 connection. 3. Fit the terminating jumper (jmp) in the correct position. 4. Connect up the power connection. 5. Connect to the H-panel via Genlink. 6. Set the RS485 port to be a Modbus master and choose one of the four required baud rates. If an old style remote annunciator is fitted the communications must be set at 4800 baud, no parity and two stop bits. Cycle the power to the H-panel for these settings to take effect. 7. Go to the HUIO configuration page. 8. Check the HUIO CONNECTED box for HUIO # and click apply (or whichever). 9. The unit is now connected and you can allocate the inputs and outputs as required. 3
8. DIAGNOSTIC MONITOR Provision has been made to fit a diagnostic PCB to the HUIO. This PCB plugs into socket J4 of the control board and also to the RS232 communication port of a PC. The controller should be power cycled AFTER plugging in the diagnostic PCB OR IT WILL NOT WORK. The unit can be interrogated either via a the manufacturer supplied custom graphical program, or by using Hyperterminal. Hyperterminal should be set for 9600 baud, eight data bits, no parity and one stop bit. The following commands are available: M* Examine memory location T* Enter production test mode S Display input/output status V Display internal voltages and hardware version C Display communication status, current baud rate and modbus address (dip switches) * These commands are reserved for the manufacturer use only and could cause mis-operation of the switch and injury or equipment damage DO NOT USE. The custom graphical program displays the screen in Figure 3. This interface will allow the HUIO outputs to be overridden for test purposes. Figure 3 Diagnostic Monitor 4
5
GENERAC POWER SYSTEMS, INC. P.O. BOX 8 WAUKESHA, WI 5387 Part No. 0G5354 Revision A (04/3/07) Printed in U.S.A.