Radio Kit with Onboard I/O

Radio Kit with Onboard I/O BR-0900-RM4 BR-2400-RM4 USER GUIDE

User Guide Your Feedback Please We always want you to feel that you made the right decision to use our products. If you have suggestions, comments, compliments or complaints about our products, documentation, or support, please write or call us. How to Contact Us ProSoft Technology, Inc. +1 (661) 716-5100 +1 (661) 716-5101 (Fax) http://www.prosoft-technology.com support@prosoft-technology.com Copyright 2018 ProSoft Technology, Inc. All rights reserved. Radio Kit with Onboard I/O User Guide ProSoft Technology Product Documentation In an effort to conserve paper, ProSoft Technology no longer includes printed manuals with our product shipments. User Manuals, Datasheets, Sample Ladder Files, and Configuration Files are provided at: http://www.prosoft-technology.com ProSoft Technology, Inc. Page 3 of 35

Wireless I/O System User Manual Page 4 of 35 ProSoft Technology, Inc.

Wireless I/O System User Manual Contents Your Feedback Please... 3 How to Contact Us... 3 ProSoft Technology Product Documentation... 3 1 Preface 7 1.1 Compliances... 8 2 System Overview 11 2.1 Highlights... 11 2.2 Hardware... 12 3 Specifications 13 3.1 Hardware and System... 13 3.2 Radio Module... 13 3.3 Analog Inputs (Radio A only)... 14 3.4 Analog Outputs (Radio B only)... 14 3.5 Digital I/O (Radios A and B)... 14 3.6 Safety and Compliance... 14 4 Installation 15 4.1 Installation... 15 4.2 DIN Rail Installation... 16 5 Radio Setup 17 6 Signal Chain Diagram 19 6.1 Analog 4-20 ma... 19 6.2 Digital/Discrete Programmable I/O (PIO)... 19 7 Wiring Diagrams 21 7.1 Power Wiring: 9-30 Vdc (reverse polarity protection)... 21 7.2 Analog 4-20 ma Input (Radio A only)... 22 7.3 Analog 4-20 ma Output Wiring (Radio B only)... 22 7.4 Digital/Discrete Input Wiring... 23 8 DIP Switch Functions 25 8.1 Digital PIO Signal Direction... 25 8.2 Digital Output Fail Safe Modes / RF Health Detection... 26 8.3 Digital Output Fail Safe Modes / RF Health Detection... 28 8.4 RF Transmit Power (900 MHz Only)... 29 8.5 RF Channel Selection (900 MHz and 2.4 GHz Only)... 29 ProSoft Technology, Inc. Page 5 of 35

Wireless I/O System User Manual 9 RF Diagnostics and Transmission Speed 31 9.1 RF Diagnostics... 31 9.2 Tx Speed: 1 Second (default) or 400 ms... 32 10 Support, Service & Warranty 33 10.1 Contacting Technical Support... 33 10.2 Warranty Information... 35 Page 6 of 35 ProSoft Technology, Inc.

Preface 1 Preface Thank you for choosing the WIO System - Radio Kit with Onboard I/O. In order to make the most of the advanced features and performance provided by this wireless I/O system, please read this user guide thoroughly before using the system. If you have any questions about this product, please call or email: ProSoft Technology, Inc. +1 (661) 716-5100 +1 (661) 716-5101 (Fax) http://www.prosoft-technology.com support@prosoft-technology.com Warning: Ensure installation of the system meets applicable state and national electrical code requirements. Warning: The installation of the system should only be performed by a qualified installer. Warning: When connecting the device to an external power supply, do not exceed the defined voltage: 9-30 Vdc max. Warning: Contains no user serviceable parts. Unauthorized modification to device or supplied accessories may damage devices and void warranty. Warning: This product is NOT intended for use in hazardous locations. Warning: Do NOT install or mount on an application with high vibration. Warning: The WIO System must be installed within an enclosure that requires a tool to access. This is to prevent inadvertent disconnection of any of the power wiring, signal wiring or communication cables. ProSoft Technology, Inc. Page 7 of 35

Preface 1.1 Compliances This device MUST be professionally installed by a factory representative or a trained authorized technician. Changes or modifications not expressly approved by the manufacturer may void the user s authority to operate the equipment. This device complies with Part 15 of the FCC Rules. Operation is subject to the following two conditions: 1) this device may not cause harmful interference, and 2) this device must accept any interference received, including interference that may cause undesired operation. To reduce potential radio interference to other users, install and use only the antenna supplied by the manufacturer to ensure successful communications. FCC RF Exposure To comply with FCC RF exposure compliance requirements, a separation distance of at least 20 cm must be maintained between the antenna of this device and all persons. FCC Interfere This equipment has been tested and found to comply with the limits for a class B digital device, pursuant to Part 15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference in a residential installation. This equipment generates, uses and can radiate radio frequency energy and if not installed and used in accordance with the instructions, may cause harmful communications to radio communications. However, there is no guarantee that interference will not occur in a particular installation. If this equipment does cause harmful interference to radio or television reception, which can be determined by turning the equipment off and on, the user is encouraged to try to correct the interference by one of the following measures: Page 8 of 35 ProSoft Technology, Inc.

Preface Reorient or relocate the antenna. Increase the separation between the equipment and receiver. Consult the manufacturer for technical help. This equipment has been certified to comply with the limits for a class B computing device, pursuant to FCC Rules. In order to maintain compliance with FCC regulations, shielded cables must be used with this equipment. Operation with non-approved equipment or use of unshielded cables is likely to result in interference to radio and television reception. The user is cautioned that changes or modifications made to the equipment without the approval of the manufacturer could void the user s authority to operate this equipment. ProSoft Technology, Inc. Page 9 of 35

System Overview 2 System Overview 2.1 Highlights Wirelessly connect I/O points in minutes securely and reliably Helps save money and time by eliminating trenching, running conduit and wire Factory-paired, point-to-point wireless I/O system (non-expandable) 2x Analog 4-20 ma I/O (Radio A to B only) 2x Digital Programmable I/O each channel can be configured to travel from Radio A to B or B to A Easy to use: no software to install or program Easy to install: mounts onto standard 35 mm DIN rails without needing tools or mounting hardware Sleek and slim design profile made to fit in tight spaces Fast response time: 1 second default or 400 ms RF transmission speed RF LED to easily diagnose wireless signal quality and speed PIO LED to easily alert when there is a signal direction error Reliable and secure wireless system using 128-bit AES to keep network protected from intrusions Fail safe operation: user has control over how outputs are failed over if RF communication is lost Fail safe output modes: o Analog: Last known value (default), < 4 ma, or > 20 ma o Digital: Off (default) or on ProSoft Technology, Inc. Page 11 of 35

System Overview 2.2 Hardware Page 12 of 35 ProSoft Technology, Inc.

Specifications 3 Specifications 3.1 Hardware and System Specification Description Analog 4-20 ma Communication 2 x Uni-Directional (Radio A to B) Digital/Discrete Communication 2 x Bi-Directional (DIP Switches) DIO Mismatch Indication - Right LED Green: OK; Red: Mismatch DIN Rail Mounting Compatibility 35 mm Standard DIN Rail (Direct Mount) Built-In Mounting Hardware Spring-Loaded Clip-On System Wire Gauge Solid / Stranded (AWG) 28-12 Gauge Wire Rating (Recommended) 300 V RMS, 80 C and 300 V, 105 C Supply Voltage Range 9 to 30 Vdc (±5 %) Reverse Polarity Protection Yes Power Consumption TBD Packaging Dimensions (WxHxD) 4.8 x 5.1 x 2.8 in; 123 x 129 x 72 mm Net Dimensions 0.7 x 3.9 x 4.5 in; 17.5 x 99 x 114 mm Packaging Weight 0.8 lbs / 363 g Net Weight (Single Radio) 0.3 lbs / 136 g Warranty 2-Year Limited 3.2 Radio Module Specification Communication Type Radio Frequency (RF) RF Security Antenna Connector Type Default Transmit Speed / Response Time Turbo Transmit Speed / Response Time Line of Sight Maximum RF Range RF Transmit Power Receiver Sensitivity Spread Spectrum Description Point-to-Point Wireless I/O Communication System 902 to 928 MHz 2.4 GHz License-Free ISM Band 128-bit AES Encryption SMA (Female Connector) 1 Second 250 ms 900 MHz: Up to 40 Miles (64.4 Km) 2.4 GHz: Up to 5.7 Mile (9.2 Km) 900 MHz: 140 mw/1 W (22 or 30 dbm - user selectable) 2.4 GHz: 63 mw (18 dbm) 900 MHz: -101 dbm 2.4 GHz: -100 dbm 900 MHz: FHSS 2.4 GHz: DSSS ProSoft Technology, Inc. Page 13 of 35

Specifications RF Link Indication - Left LED RF Timeout Trigger RF Response Time RF Signal Quality Green: OK Solid Yellow: Failed 10 Seconds Flashing Normal (1 sec) Flashing Fast (250 ms) Flashing Green: Strong Flashing Yellow: Weak 3.3 Analog Inputs (Radio A only) Specification 2x Analog Inputs Accuracy Internal Loop Power AI Input Impedance (loop) Description 4 to 20 ma (16-bit Resolution) < 0.2 % of Full Scale 9 to 30 Vdc (Depends on Supply Voltage) 250 Ohm 3.4 Analog Outputs (Radio B only) Specification 2x Analog Outputs Description Output Terminal Voltage Range 10 Vdc Min. 30 Vdc Max. RF Fail-Safe Output Modes 4 to 20 ma (16-bit Resolution) Last Known Value (Def.), < 4 ma, > 20 ma (DIP) 3.5 Digital I/O (Radios A and B) Specification I/O Channel Count Signal Direction Input Voltage Range Input Voltage Threshold Output Rating Fail-Safe Output Modes Description 2x Configurable Channels on Each Radio Module Any Direction, Any Combination (If A = In; B = Out) Signal Direction Controlled via DIP Switches 3 to 30 VDC Signal ("H"): TBD 0 Signal ("L"): < 1.1 VDC 1 A Sink Current for Open-Drain Outputs / NPN On or Off (DIP Switch Controlled) 3.6 Safety and Compliance Specification Description FCC FCC Part 15 Industry Canada (IC) ICES-003 RoHS CSA (Canada and US) Page 14 of 35 ProSoft Technology, Inc.

Installation 4 Installation 4.1 Installation 1. Install or use existing NEMA-type enclosure. 2. Be sure the WIO System meets applicable grounding requirements in the enclosure. 3. Install a 35 mm x 7.5 mm DIN rail inside the enclosure. 4. Mount WIO Radio Module onto the DIN rail. 5. Install antenna at least 10 ft above ground (performing a RF site survey prior to installation is highly recommended). There are various types of antennas including bulkhead, omni, and yagi. Please use the appropriate type for your application. 6. Connect Antenna to Radio Module using appropriate high quality, low loss antenna cables. 7. Connecting a lightning arrestor between Radio and Antenna is strongly recommended when antenna mounted outdoors. 8. Run wires through the bottom of the enclosure and be sure to weather seal any openings as needed. 9. Connect signal wires to the Radio Module. 10. Supply power to the Radio Module: 9-30 Vdc. 11. Repeat above steps for other Radio Module location. ProSoft Technology, Inc. Page 15 of 35

Installation 4.2 DIN Rail Installation The WIO Radio Module can be removed from the din rail by inserting the tip of a flathead screwdriver into removal slot located on the metal latching clip. Page 16 of 35 ProSoft Technology, Inc.

Radio Setup 5 Radio Setup 1. Perform a RF site survey prior to installation. 2. Use high quality antennas and low loss cables and fittings for achieving the best possible wireless performance. 3. Having a clear line of sight between antennas (Fresnel zone) is ideal for achieving best RF signal quality. 4. When setting up and installing antennas, avoid walls, tall buildings, trees, and other solid obstructions for improving RF signal quality. 5. Install antennas at least 10 ft above ground when possible. 6. When using directional antennas, be sure to point the antennas at each other and be sure to use correct antenna orientation. 7. Be sure to install omni-directional antennas in vertical position or perpendicular to the ground. 8. Be sure that there are no loose connections. Securely tighten all cable connections and wire terminals. 9. Be sure to waterproof all exterior cable connection using high quality sealing tape. 10. Once the WIO System is up and running, use the left LED to diagnose RF health. ProSoft Technology, Inc. Page 17 of 35

Page 18 of 35 ProSoft Technology, Inc.

Signal Chain Diagram 6 Signal Chain Diagram 6.1 Analog 4-20 ma Analog signals travel only in one direction from Radio A to Radio B. 6.2 Digital/Discrete Programmable I/O (PIO) The direction of digital signals are programmable by channel, meaning they can travel in either direction based on DIP switch configuration: Radio A to B or Radio B to A. ProSoft Technology, Inc. Page 19 of 35

Signal Chain Diagram Page 20 of 35 ProSoft Technology, Inc.

Wiring Diagrams 7 Wiring Diagrams 7.1 Power Wiring: 9-30 Vdc (reverse polarity protection) 1. To reset the device, you can power cycle the device or press and hold Tx button down for ~4 seconds until the LEDs are extinguished. 2. Device must be reset after modifying any DIP switch settings. ProSoft Technology, Inc. Page 21 of 35

Wiring Diagrams 7.2 Analog 4-20 ma Input (Radio A only) 7.3 Analog 4-20 ma Output Wiring (Radio B only) Page 22 of 35 ProSoft Technology, Inc.

Wiring Diagrams 7.4 Digital/Discrete Input Wiring 1. PIO DIP switch must be set to Input 2. Digital/Discrete Output Wiring a. PIO DIP switch must be set to Output ProSoft Technology, Inc. Page 23 of 35

Wiring Diagrams Page 24 of 35 ProSoft Technology, Inc.

DIP Switch Functions 8 DIP Switch Functions The device must be reset or power-cycled after modifying any DIP switch settings. 8.1 Digital PIO Signal Direction 1. Controlled by DIP Switches 1 and 2. a. Factory Default: Radio A = Inputs ; Radio B = Outputs. b. The system supports any combination of signal directions. *Note that DIP Switch Input/Output positions are reversed on Radio A and B. ProSoft Technology, Inc. Page 25 of 35

DIP Switch Functions 2. Signal direction must always be opposite of each other. Must always be In-Out / Out- In and not In-In / Out-Out (PIO diagnostic LED will flash solid red). 8.2 Digital Output Fail Safe Modes / RF Health Detection 1. Controlled by DIP Switch 3. a. DIP Switch controls fail over operation for both PIO 1 and 2. b. When Radio communication is lost for 10 seconds or more, the Radio Module will automatically place the outputs to user-configured fail safe states. Page 26 of 35 ProSoft Technology, Inc.

DIP Switch Functions 2. How to Monitor RF Health using a PIO channel a. To continuously monitor RF health of the system, you can use an available PIO channel for this purpose. You can monitor the RF health from either Radio Module. When RF communication is restored, the operation returns to normal. ProSoft Technology, Inc. Page 27 of 35

DIP Switch Functions 8.3 Digital Output Fail Safe Modes / RF Health Detection 1. Analog Output Fail Safe Modes a. Radio B only: Controlled by DIP Switches 4 and 5. b. When Radio communication is lost for 10 seconds or more, the Radio Module will automatically place the outputs to user-configured fail safe values. c. Examples of fail safe configurations based on DIP switch positions Page 28 of 35 ProSoft Technology, Inc.

DIP Switch Functions 8.4 RF Transmit Power (900 MHz Only) 1. 900 MHz only: Controlled by DIP Switch 6. 2. 140 mw (default) or 1 W option. 3. Transmit power setting must match on both Radio Modules. 4. 2.4 GHz system s transmit power is fixed at 63 mw. 8.5 RF Channel Selection (900 MHz and 2.4 GHz Only) 1. Radio channel pattern MUST MATCH on both Radio Modules 2. 900 MHz: controlled by DIP Switches 7 and 8 (channels 0 to 3) ProSoft Technology, Inc. Page 29 of 35

DIP Switch Functions 3. 2.4 GHz: controlled by DIP Switches 6, 7 and 8 (channels 0 to 7) 4. Examples of how to select RF channel/pattern (2.4 GHZ shown) ID or DIP pattern on both Radio Modules must match: Page 30 of 35 ProSoft Technology, Inc.

RF Diagnostics and Transmission Speed 9 RF Diagnostics and Transmission Speed 9.1 RF Diagnostics 1. RF health can easily be diagnosed using the left LED located on the front panel. a. Be sure both antennas are installed properly and connected securely to the Radio Modules. b. Be sure to supply power to both Radio Modules (9-30 Vdc). c. Use the RF LED to evaluate the signal quality of the RF communication d. Performing steps i-iii is the simplest form of doing a site survey prior to installation 2. When left LED is green, then RF is in good condition. a. Green LED indicates a strong to medium RF signal quality (-40 db (best) to -94 db). b. Speed of flashing LED indicates Tx speed (1 second or 400 ms). 3. When left LED is yellow, it requires attention. a. Flashing yellow indicate a weak RF signal (worse than -94 db). b. Solid yellow indicates RF failure. i. Triggered when RF communication is lost for 10 consecutive seconds or more. ii. Automatically drives signal outputs to user-configured fail safe states. c. When left LED is yellow. i. Re-check all cable connections between antenna and Radio Module. ii. Radio Modules may be out of RF range. iii. Surrounding area may have many RF interferences and, or obstacles. iv. If using 900 MHz or 2.4 GHz system, try using a different RF channel. ProSoft Technology, Inc. Page 31 of 35

RF Diagnostics and Transmission Speed 9.2 Tx Speed: 1 Second (default) or 400 ms 1. Tx speed is controlled by the Tx Button located on the front of the Radio Module. a. Use a small pin or a screwdriver to press the button to toggle between Tx speeds. i. Using faster Tx speed consumes more power. b. Changing the speed on either Radio Module will update the other Radio Module. Page 32 of 35 ProSoft Technology, Inc.

Support, Service & Warranty 10 Support, Service & Warranty 10.1 Contacting Technical Support ProSoft Technology, Inc. (ProSoft) is committed to providing the most efficient and effective support possible. Before calling, please gather the following information to assist in expediting this process: 1 Product Version Number 2 System architecture 3 Network details If the issue is hardware related, we will also need information regarding: 1 Module configuration 2 Module operation and any unusual behavior 3 Configuration/Debug status information 4 LED patterns 5 Details and wiring schematic for the I/O devices interfaced to the module. Note: For technical support calls within the United States, ProSoft s 24/7 after-hours phone support is available for urgent plant-down issues. Detailed contact information for all our worldwide locations is available on the following page. ProSoft Technology, Inc. Page 33 of 35

Support, Service & Warranty Asia Pacific Regional Office Phone: +603.7724.2080 asiapc@prosoft-technology.com Languages spoken: Bahasa, Chinese, English, Japanese, Korean REGIONAL TECH SUPPORT support.ap@prosoft-technology.com North Asia (China, Hong Kong) Phone: +86.21.5187.7337 china@prosoft-technology.com Languages spoken: Chinese, English REGIONAL TECH SUPPORT support.ap@prosoft-technology.com Southwest Asia (India, Pakistan) Phone: +91.98.1063.7873 india@prosoft-technology.com Languages spoken: English, Hindi, Urdu Australasia (Australia, New Zealand) Phone: +603.7724.2080 pacific@prosoft-technology.com Language spoken: English Southeast Asia (Singapore, Indonesia, Philippines) Phone: +603.7724.2080 seasia@prosoft-technology.com Languages spoken: English, Bahasa, Tamil Northeast & Southeast Asia (Japan, Taiwan, Thailand, Vietnam, Malaysia) Phone: +603.7724.2080 neasia@prosoft-technology.com Languages spoken: English, Chinese, Japanese Korea Phone: +603.7724.2080 korea@prosoft-technology.com Languages spoken: English, Korean Europe / Middle East / Africa Regional Office Phone: +33.(0)5.34.36.87.20 europe@prosoft-technology.com Languages spoken: French, English REGIONAL TECH SUPPORT support.emea@prosoft-technology.com Middle East & Africa Phone: +971.4.214.6911 mea@prosoft-technology.com Languages spoken: Hindi, English REGIONAL TECH SUPPORT support.emea@prosoft-technology.com North Western Europe (UK, IE, IS, DK, NO, SE) Phone: +44.(0)7415.864.902 nweurope@prosoft-technology.com Language spoken: English Central & Eastern Europe, Finland Phone: +48.22.250.2546 centraleurope@prosoft-technology.com Languages spoken: Polish, English, Russia & CIS Phone: +7.499.704.53.46 russia@prosoft-technology.com Languages spoken: Russian, English Austria, Germany, Switzerland Phone: +33.(0)5.34.36.87.20 germany@prosoft-technology.com Language spoken: English, German BeNeLux, France, North Africa Phone: +33(0)5.34.36.87.27 france@prosoft-technology.com Languages spoken: French, English Mediterranean Countries Phone: +39.342.8651.595 italy@prosoft-technology.com Languages spoken: Italian, English, Spanish Page 34 of 35 ProSoft Technology, Inc.

Support, Service & Warranty Latin America Regional Office Phone: +52.222.264.1814 support.la@prosoft-technology.com Languages spoken: Spanish, English REGIONAL TECH SUPPORT support.la@prosoft-technology.com North America Regional Office Phone: +1.661.716.5100 info@prosoft-technology.com Languages spoken: English, Spanish REGIONAL TECH SUPPORT support@prosoft-technology.com Brazil Phone: +55.11.5084.5178 brasil@prosoft-technology.com Languages spoken: Portuguese, English REGIONAL TECH SUPPORT support.la@prosoft-technology.com Mexico Phone: +52.222.264.1814 mexico@prosoft-technology.com Languages spoken: Spanish, English REGIONAL TECH SUPPORT support.la@prosoft-technology.com Andean Countries, Central America & Caribbean Phone: +507.6427.48.38 andean@prosoft-technology.com Languages spoken: Spanish, English Southern Cone (Argentina, Bolivia, Chile, Paraguay & Uruguay) Phone: +54.911.4565.8119 scone@prosoft-technology.com Languages spoken: Spanish, English 10.2 Warranty Information For complete details regarding ProSoft Technology s TERMS & CONDITIONS OF SALE, WARRANTY, SUPPORT, SERVICE AND RETURN MATERIAL AUTHORIZATION INSTRUCTIONS, please go to: www.prosoft-technology.com/legal All documentation is subject to change without notice. ProSoft Technology, Inc. Page 35 of 35