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M4RTU/M4 I/O User’s Guide

29

INSTALLATION AND SETUP

OVERVIEW

This chapter expands upon the quick start information in Chapter 2 with detailed instructions on installing and
configuring the base M4RTU/M4 I/O. It also introduces procedures for installing optional expansion cards and
connecting the optional M4RTUX Extender I/O unit. Detailed instructions on installing these optional units are
provided in each unit’s data sheet.

After unpacking the M4RTU/M4 I/O and power supply, review the packing list in Chapter 2 to ensure that all
components are included. You may then proceed through the installation procedures below, as detailed in this
chapter:

•

Installing the power supply

•

Connecting the backup battery

•

Setting configuration jumpers and switches

•

(Optional)

Installing expansion cards

•

(Optional)

Connecting the M4RTUXCAB cable to the M4RTU/M4 I/O base unit

•

Mounting the M4RTU/M4 I/O base unit

•

Connecting power to the M4RTU/M4 I/O

•

Installing I/O modules

•

Connecting field wiring

•

Connecting to a host PC or modem

•

(Optional)

Connecting to Opto 22 I/O.

CHAPTER 3

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Summary of Contents for Modular M4RTU

Page 1: ...iness Park Drive Temecula CA 92590 3614 Phone 800 321 OPTO 6786 or 951 695 3000 Fax 800 832 OPTO 6786 or 951 695 2712 www opto22 com Product Support Services 800 TEK OPTO 835 6786 or 951 695 3080 Fax...

Page 2: ...ic warranty information Refer to Opto 22 form number 1042 for complete warranty information Opto 22 FactoryFloor Cyrano Optomux and Pamux are registered trademarks of Opto 22 Generation 4 ioControl io...

Page 3: ...ist 20 Component Use 20 Installing the Power Supply 21 Connecting the Battery 22 Checking Configuration Jumpers 23 Installing Daughter Cards and or I O Extender 23 Mounting the M4RTU m4 I O 24 Connect...

Page 4: ...ting to Opto 22 I O Units 54 LED Indicators 56 Chapter 4 Software and Firmware 57 Overview 57 OptoControl 58 Configuring Communications to the M4RTU M4 I O 58 Configuring the M4RTU M4 I O and M4RTUX 5...

Page 5: ...hooting 75 Appendix B Cable and Connector Specifications 77 Serial Communication Cables 77 Two Pair 77 Three Pair 77 Four Pair 77 M4RTU M4 I O Connectors 78 Appendix C Product Specifications 79 Append...

Page 6: ...6 M4RTU M4 I O User s Guide TABLE OF CONTENTS...

Page 7: ...pter cards are available providing a wide range of communication options ABOUT THIS MANUAL This reference manual provides complete specifications and instructions to set up and install a M4RTU or M4 I...

Page 8: ...ration Jumper settings for all addresses Appendix E Upgrading RAM and Flash EEPROM Instructions for replacing RAM and Flash EEPROM upgrade chips Appendix F Worksheets Worksheets that can be used to pl...

Page 9: ...l a graphical flowchart based development environment for control solutions OptoDisplay a graphical multimedia operator interface package OptoServer a robust data server that connects the controller n...

Page 10: ...user to remotely download new kernels offered by Opto 22 This avoids the needtovisitanM4RTU M4I Ositetodownloadanewkernelthatoffersfeaturesrequiredforagivenapplication The M4RTU M4 I O base unit acco...

Page 11: ...andafiberopticARCNET repeater card M4SARCFR These open options allow customers to share real time data with telemetry based SCADA systems or network based control and information systems The availabl...

Page 12: ...Server and the communications enabling technologies inherent in Windows Using OptoServer the data server that connects the controller network with the PC based FactoryFloor network you can develop cli...

Page 13: ...radio frequency transceivers and direct serial connections to PC hardware ThedesignoftheM4RTU M4I OisalsoconducivetointegrationwithOpto 22 sdigitalandanalogI Osystems aswellaswithotherintelligentequip...

Page 14: ...14 M4RTU M4 I O User s Guide INTRODUCTION Figure 1 3 M4RTU M4 I O Communications Configurations...

Page 15: ...M4RTU M4 I O User s Guide 15 Figure 1 4 Integration of M4RTU M4 I O with Expanded I O Figure 1 5 Integration of M4RTU M4 I O with Other Devices INTRODUCTION...

Page 16: ...he powerful two processor architecture allows the main processor to off load onto the I O processor such tasks as counting frequency and pulse measurement latching totalizing time proportional output...

Page 17: ...AMS M4RTU M4 I O Base Unit Overview Figure 1 7 shows the basic components of the M4RTU M4 I O as viewed from the end of the unit with the expansion slot and serial connector Figure1 7 M4RTU M4 I O as...

Page 18: ...UCTION Figure 1 8 shows the basic components of the M4RTU M4 I O as viewed from the end of the unit with the power supply and M4RTUX expansion connector Figure 1 8 M4RTU M4 I O as Viewed from End with...

Page 19: ...for field wiring and communication setup instructions and diagrams A quick start installation consists of the following steps 1 Unpacking the M4RTU M4 I O and power supply 2 Installing the power supp...

Page 20: ...N 8848 Contains OptoUtilities 32 bit utility used to download OptoControl firmware Floppy disk P N 8887 Contains Cyrano firmware and DOS utility to download firmware Customer update sheet Contains lat...

Page 21: ...supply Slide the power supply into the cavity of the M4RTU M4 I O until it seats completely 3 Use the four screws provided to fasten the power supply from the underside of the M4RTU M4 I O 4 Secure th...

Page 22: ...the factory You will need to connect it yourself Refer to Figure 2 3 below to determine the location of the battery and its connection For detailed information on connecting the battery see Chapter 3...

Page 23: ...have purchased optional expansion daughter cards for the M4RTU M4 I O you will now need to install them Refer to the appropriate document listed below for detailed installation instructions M4SSER see...

Page 24: ...e or panel either vertically or horizontally using the mounting flanges shown in Figure 2 5 below Use the mounting template provided to prepare the mounting site Using user supplied 1 4 20 screws fast...

Page 25: ...I O COM0 serial port Refer to the table below to determine the function of each COM0 pin connection Table 2 2 Pin Connections for the M4RTU M4 I O COM0 Serial Port 1 Data Carrier Detect DCD 2 Transmit...

Page 26: ...e diagram below to wire the M4RTU M4 I O RS 232 serial port to the serial connector on the PC Verify that the pin connections at the host PC are the same as those called out in the diagram Important I...

Page 27: ...een the PC and M4RTU M4 I O do the following 1 Cycle the M4RTU M4 I O power by flipping the power switch off and then on see Figure 2 8 Remember that the configuration jumpers and switches must be set...

Page 28: ...ch as the M4 controller s kernel version the name of the current strategy and the controller s current date and time If the communication is working correctly the time should update every one or two s...

Page 29: ...After unpacking the M4RTU M4 I O and power supply review the packing list in Chapter 2 to ensure that all components are included You may then proceed through the installation procedures below as deta...

Page 30: ...1 and 3 2 provide two views of the M4RTU M4 I O base unit with all components clearly labeled Figure 3 2 M4RTU M4 I O as Viewed from End with Power Supply and M4RTUX Connectors Figure 3 1 M4RTU M4 I...

Page 31: ...in DIN connector Slide the power supply into the cavity until it seats firmly against the connector This will automatically align the four power supply screw holes located on the underside of the M4RT...

Page 32: ...32 M4RTU M4 I O User s Guide INSTALLATION AND SETUP Figure 3 3 Installing the Power Supply on the M4RTU M4 I O...

Page 33: ...eryconnectionlabeledJ2 Theconnection wire will attach in one direction only with the red wire connecting to the positive lead Refer to Figure 3 4 to confirm battery and battery connection locations Th...

Page 34: ...pers Toaccessthesejumpers removethetop cover of the M4RTU M4 I O by removing the four corner screws Note that a sticker is affixed to the underside of the cover to summarize the function of these jump...

Page 35: ...t Loader In Boot to kernel Out Boot to loader H0 H1 Host Port H0 H1 In In COM0 Out In COM1 In Out ARCNET Out Out Ethernet Baud 0 3 Baud Rate 0 1 2 3 Out In In In 115 2 KBd In Out In In 76 8 KBd Out Ou...

Page 36: ...ignored For more detailed information refer to the OptoControl Command Reference Manual Communications Overview Boot Loader Jumper X1 Use this jumper to set the controller to either boot to the downlo...

Page 37: ...ificantbitissevenandtheleastsignificantbitiszero addresszero is reserved and should not used Refer to Figure 3 6 Processor Board Jumpers Four additional jumpers are located on the main processor board...

Page 38: ...M Jumper RJ RJ identifies the AMOUNT of EPROM memory installed and hence the TYPE of EPROM chips or vice versa RJ installed indicates 256 KB Kbytes which is in the form of 2 chips that are 1 megabit e...

Page 39: ...terminated and biased Terminate the port when it is physically the first or last unit in an RS 485 multi drop serial network application In the OUT position the RS 485 lines will be floating This set...

Page 40: ...ou may also need to remove one or two additional end caps to achieve proper card alignment 3 Align the edges of the card with the U channels on the sides of the expansion bus cavity Slide the card all...

Page 41: ...unit right away or at some later time Brief procedures for connecting the M4RTUXCAB cable are provided below along with a diagram illustrating where the cable should be attached For complete details...

Page 42: ...4RTUXCABontheM4RTU M4 I O before mounting the unit The general procedure for mounting the M4RTU M4 I O base unit is as follows 1 Determine panel mounting site and orientation horizontal or vertical Be...

Page 43: ...M4RTU M4 I O User s Guide 43 INSTALLATION AND SETUP Figure 3 10 M4RTU M4 I O Dimensions and Mounting Information...

Page 44: ...ch power supply wire being careful not to strip back the insulation too far 4 Insert each wire into the appropriate terminal block location and tighten by turning the power terminal screw clockwise Ma...

Page 45: ...own below To install I O modules you do not need to remove the top cover unless you will be changing field wiring at the same time Install each digital or analog module as follows 1 Choose the appropr...

Page 46: ...hetopoftheM4RTU M4I Oboardnexttothecorresponding digital or analog channels These terminals allow field wires to be connected to the installed I O modules Figure 3 13 shows the location of the termina...

Page 47: ...nnel zero wired with VIN on terminal 1 and VIN on terminal 2 Analog Modules Analog modules can use up to four terminals per I O point Figure 3 15 shows a G4AD6 0 5 VDC analog input module in channel z...

Page 48: ...pto 22controllersmaynotbecompatiblewiththeM4RTU M4 I O Use the M4RTU M4 I O connectors provided and refer to the diagrams in this manual for wiring information The following sections describe wiring f...

Page 49: ...s descriptions for each COM1 pin for both 2 wire and 4 wire modes Note that the interrupt lines can be used to add interrupt capability to Opto 22 I O units connected to an M4RTU M4 I O via an RS 485...

Page 50: ...cation See Appendix B for a complete list of recommended cables RS 232 COM0 Make RS 232 communication connections to a host PC by using the RS 232 COM0 default host connector on the M4RTU M4 I O Refer...

Page 51: ...r to the converter and the other end with a pluggable terminal block to the M4RTU M4 I O Refer to Figure 3 18 and Figure 3 19 for wiring details 2 Wire Mode Using an AC37 The AC37 also supports a 2 wi...

Page 52: ...and initializationsetup YoumayalsowishtorefertoOpto 22 scommunicationapplicationnotes availablethrough Opto 22 s Bulletin Board Service see Appendix G for details Most standard external PC modems can...

Page 53: ...Data RD 4 Request to Send RTS 5 Clear to Send CTS 6 Data Set Ready DSR 7 Signal Common 8 Data Carrier Detect DCD 20 Data Terminal Ready DTR 22 Ring Indicator RI RS 232 9 pin Pin Name Abbreviation 1 Da...

Page 54: ...istic 200 I O Remote Interface board G4IOR as illustrated in Figure 3 20 This method allows the use of Opto 22 I O equipment G4 panels cables etc Figure 3 20 shows a 2 wire RS 485 shielded connection...

Page 55: ...ure 3 21 This allows you to accommodate your own installation practices application requirements and cables Simply mount your I O units throughout your installation and daisy chain communication cable...

Page 56: ...is indicator illuminates whenever COM0 is transmitting serial data If the LED fails to illuminate it could indicate that the port is idle a wiring problem exists or CTS is low RX0 COM0 receive This in...

Page 57: ...easy to use it also prevents multiple database entry errors allows tag name validation and takes full advantage of the M4RTU M4 I O s hardware capabilities The sophisticated firmware of both the main...

Page 58: ...nstalled into each I O channel on each unit Once OptoControl has this information you may use the assigned I O tag names to reference the I O within an OptoControl strategy Note that the multifunction...

Page 59: ...d for the M4RTU M4 I O in RAM remotely downloaded and debugged and then stored remotely in flash memory If the M4RTU M4 I O has been set up to boot automatically from flash memory the OptoControl stra...

Page 60: ...e Refer to Appendix G for details Eachprocessorhasabootloaderstoredintoanondestructivepartofitsflashmemory Thisbootloaderenables a user to update the firmware as Opto 22 makes new firmware files avail...

Page 61: ...l of the M4RTU M4 I O and M4RTUX should the need arise A bused four position pluggable terminal block is provided on both the M4RTU M4 I O and M4RTUX This bused terminal block is located between the t...

Page 62: ...4 I O User s Guide FIELD WIRING Figure 5 1 Locations of Terminals on M4RTU M4 I O Showing Logical Representation of Modules Figure 5 2 Locations of Terminals on M4RTUX Showing Logical Representation o...

Page 63: ...log channels labeled 0 3 correspond correctly to digital modules 0 7 and analog modules 0 3 while on the M4RTUX the channels with the same labels correspond logically to digital modules 8 15 and analo...

Page 64: ...e appropriate section in this chapter for the specific model of G4 digital or analog module for which wiring will be connected Also refer to Appendix F for a field wiring worksheet 3 Ensure that each...

Page 65: ...0 and an AC input module wired to channel 1 on the M4RTU M4 I O For the digital input modules listed in Table 5 1 the input device may be wired to either terminal The polarity of the power does not m...

Page 66: ...de For DC output modules used with inductive loads add a commutating diode typically a 1N4005 to the circuit as shown on the channel 6 connection to the M4RTUX FIELD WIRING Figure 5 4 Wiring for DC an...

Page 67: ...Figure 5 5 to wire the digital quadrature input module model G4IDC5Q The example shows the module connected to channels 8 and 9 on the M4RTUX Note This module requires two digital channels FIELD WIRIN...

Page 68: ...e Figure 5 6 to wire the analog voltage input or output modules listed in Table 9 3 The diagram shows a voltage input module wired to channel 0 and a voltage output module wired to channel 3 on the M4...

Page 69: ...hows wiring to the M4RTU M4 I O on channels 0 through 3 The current loop for an input or output current device can be powered either by a user s external supply or by the module Using the module reduc...

Page 70: ...ime dV dt Typically potentiometer based transducers are attached An example of an application would be a transducer measuring piston velocity in an air hydraulic cylinder Use Figure 5 8 to wire the ve...

Page 71: ...temperature input module model G4AD4 to an Opto 22 ICTD probe The example shows wiring to channel 0 on the M4RTU M4 I O Table 5 5 Thermocouple Input Data Model T C Type Polarity Color G4AD5 J white re...

Page 72: ...type of connection to channel 7 on the M4RTUX Rate Module The rate module model G4AD20 measures the frequency of an incoming signal and produces a count based on the number of cycles per second Hertz...

Page 73: ...ut modules switch either 5 60 VDC G4DA9 or 12 280 VAC G4DA10 Together with power SSRs they are ideal for temperature control applications such as heating Use Figure 5 12 to wire either of the analog t...

Page 74: ...74 M4RTU M4 I O User s Guide FIELD WIRING...

Page 75: ...M4RTU M4 I O connections are incorrect Incorrect setup in the OptoControl controller configurations Check wiring connections for correct polarity and wire integrity Check controller configurations sp...

Page 76: ...rrectly Device is not properly matched to module type I O or processor board is bad Check wiring to output device Test module using meter and test software OptoControl or G4TEST Change voltage to matc...

Page 77: ...e one of the extra wires rather than the shield for the common Two Pair Belden P N 8102 with overall shield Belden P N 9729 individually shielded Belden P N 8162 individually shielded with overall shi...

Page 78: ...ns from the M4RTU M4 I O COM0 and COM1 and the M4SSER COM2 and COM3 Manufactured by Phoenix Contact P N MC1 5 7 ST 3 81 Green Pluggable 3 Position Terminal Plug Used for M4RTU M4 I O power connection...

Page 79: ...ports using Opto 22 I O Communication Base unit Expansion Modem support 1 RS 232 and 1 RS 485 422 port Via daughter cards configurable serial ports and ARCNET Direct lease and radio Real time clock C...

Page 80: ...80 M4RTU M4 I O User s Guide PRODUCT SPECIFICATIONS...

Page 81: ...4 I O includes eight address jumpers as described in Chapter 3 To set the jumpers based on a predetermined address refer to the chart below For details on accessing and setting these jumpers see Chapt...

Page 82: ...82 M4RTU M4 I O User s Guide ADDRESS JUMPER CONFIGURATION...

Page 83: ...this process to upgrade the processor board with flash chips containing new enhanced boot loaders supporting new primary host communication hardware e g fiber or Ethernet To disassemble the M4RTU M4...

Page 84: ...efully remove the U13 and U15 chips for a RAM upgrade or the U12 and U14 chips for a flash EEPROM upgrade 10 When upgrading flash EEPROM install each chip in its correct position U12 or U14 Each will...

Page 85: ...A 4M G4LC32RAMEX4M G4RAM4M N A N A N A N A N A Use Table E 2 to select EPROM expansion options for your controller Table E 2 EPROM Expansion Options Size G4LC32 G4LC32SX G4LC32ISA M4RTU M4IO M4 Origin...

Page 86: ...86 M4RTU M4 I O User s Guide UPGRADING RAM AND FLASH EEPROM...

Page 87: ...he digital or analog I O type in the box to the right of each I O channel shown on the worksheet The following is an example of a completed worksheet When configuring digital or analog I O for the M4R...

Page 88: ...digital or analog I O for the M4RTU M4 I O base unit using OptoControl use these addresses and make sure the PORT type is LOCAL See Chapter 4 Software and Firmware for more information Figure F 2 M4R...

Page 89: ...M4RTU M4 I O User s Guide 89 WORKSHEETS Figure F 3 M4RTUX I O Extender I O Module Worksheet...

Page 90: ...installation for the M4RTU M4 I O base unit and M4RTUX I O Extender Worksheet Instructions Fill in the wire name boxes for each terminal The Field Wiring Worksheet can be used by your installer durin...

Page 91: ...M4RTU M4 I O User s Guide 91 WORKSHEETS Figure F 5 Field Wiring Worksheet Example 2...

Page 92: ...Watts W Quantity Q Total W x Q M4RTU M4 I O Base Unit 7 5 1 0 7 5 M4RTUX I O Extender Unit 0 0 Daughter Cards M4SSER 1 6 M4SARC 1 0 M4SARCF 1 1 M4SARCFR 1 6 M4SENETC 3 1 M4SENETU 1 50 M4DUALARC 0 7 M4...

Page 93: ...Eight G4 digital module totals 0 688 W Four G4ADX analog modules total 6 4 W 3 Add the values in the Total column including the value entered for the M4RTU M4 I O base unit and enter the result on th...

Page 94: ...94 M4RTU M4 I O User s Guide WORKSHEETS...

Page 95: ...calling for technical support be prepared to provide the following information about your system to the Product Support engineer Software and version being used Controller firmware version PC configur...

Page 96: ...96 M4RTU M4 I O User s Guide PRODUCT SUPPORT...

Page 97: ...necting field wiring 46 50 64 connecting power to the M4RTU DAS 44 50 connectors specifications 78 control program 36 57 60 current input module 70 Cyrano 60 kernel 20 D digital I O modules 10 wiring...

Page 98: ...iagram 16 17 cable and connector specifications 77 communications configuring through OptoControl 58 60 connecting field wiring to 46 50 connecting power to 44 diagram of terminals on 62 disassembling...

Page 99: ...board 10 product specifications 79 Product Support 95 Q quadrature input module 67 quick start 19 28 R RAM 36 chips location of 83 jumpers 38 upgrading 83 rate module 72 remote bus 10 serial link 58...

Page 100: ...2 termination switches 39 thermocouple input module 70 thermocouple input modules 70 table of 71 time proportional output modules 73 troubleshooting 75 76 two way dial up capability 12 typical applica...

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