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RediGate 400 Series Industrial Data Gateway

Hardware Manual

RediGate 400 Hardware Manual 81-0030-03 Rev. A

Product Information

Full information about other Elecsys products is available on our website at www.elecsyscorp.com

Useful Contact Information

Product Support

Tel: +1-913-890-8905

Toll free: +1-800-338-8969

Fax: +1-913-982-5766

Email: [email protected]

Headquarters, Sales, Support & Manufacturing

Elecsys Corporation

846 N Mart-Way Court

Olathe, KS 66061

Tel: +1-913-647-0158

Fax: +1-913-982-5766

Email: [email protected]

While Elecsys may assist customers with their choice of products, the final choice of product for a

specific application is entirely the responsibility of the buyer. Elecsys’ entire liability with respect to its

products or systems is defined in the Elecsys standard terms and conditions of sale.

Any example code is provided only to illustrate the use of Elecsys products. No warranty, either

expressed or implied, is made regarding any example code provided by Elecsys and Elecsys shall incur

no liability whatsoever arising from any use made of this code.

© 2016 Elecsys Corporation


Contents

1 Revision History ................................................................................................................. 5

2 Preface ................................................................................................................................ 6

2.1 Scope of this Manual ............................................................................................................ 6

2.2 Name Conventions ............................................................................................................... 6

2.3 Electrostatic Discharge (ESD) Protection ............................................................................. 6

2.4 Electromagnetic Compatibility (EMC) ................................................................................... 6

2.4.1 Radio Frequency Requirements ....................................................................................... 6

2.5 Disclaimers........................................................................................................................... 7

3 Introduction ........................................................................................................................ 8

3.1 RediGate 400 Model Options ............................................................................................... 8

3.2 Accessory Options ............................................................................................................... 9

4 Specifications ................................................................................................................... 10

4.1 Enclosure / Dimensions ...................................................................................................... 10

4.1.1 Dimensions .................................................................................................................... 10

4.1.2 Mounting Instructions ..................................................................................................... 12

4.1.3 Compliance with Hazardous Area Standards.................................................................. 13

4.2 System Specifications ........................................................................................................ 15

4.2.1 General Features: .......................................................................................................... 15

4.2.2 Power ............................................................................................................................. 15

4.2.3 Environmental Characteristics ........................................................................................ 16

5 Base RediGate 400 Hardware .......................................................................................... 17

5.1 Ethernet Ports .................................................................................................................... 17

5.2 Serial Ports......................................................................................................................... 18

5.2.1 RS-232 Serial Interfaces ................................................................................................ 18

5.2.2 RS-485/RS-422 Serial Interfaces .................................................................................... 19

5.2.3 RS-485/422 Wiring Diagrams ......................................................................................... 20

5.3 Real-time Clock .................................................................................................................. 22

6 Optional RediGate 400 Hardware .................................................................................... 23

6.1 Serial Port Expansion ......................................................................................................... 23

6.2 Cellular Modem .................................................................................................................. 23

6.2.1 Cellular Account Activation ............................................................................................. 23

6.2.2 Cellular and GPS Antennas ............................................................................................ 24

6.3 MULTI-I/O Board ................................................................................................................ 24

6.3.1 Multi-I/O Specifications ................................................................................................... 24

6.3.2 Multi-I/O Wiring ............................................................................................................... 26

6.3.3 Multi-I/O Software Access .............................................................................................. 28

6.4 Relay8/IN8 Board ............................................................................................................... 30

6.4.1 Relay8/IN8 Specifications ............................................................................................... 30


6.4.2 Relay8/IN8 Wiring .......................................................................................................... 31

6.4.3 Relay8/IN8 Software Access .......................................................................................... 33


1 Revision History

Revision Comments

A Initial release of Elecsys RediGate 400 Hardware Manual


2 Preface

2.1 Scope of this Manual

This manual describes the standard hardware configuration of the Elecsys RediGate 400 Series

Industrial Data Gateway and optional hardware.

2.2 Name Conventions

All numbers are in decimal unless otherwise indicated. Where a number is prefixed by ‘0x’, the

value is in hexadecimal format.

2.3 Electrostatic Discharge (ESD) Protection

These units contain devices that could be damaged by the discharge of static electricity. At all

times, please observe industry standard ESD precautions when handling the unit.

2.4 Electromagnetic Compatibility (EMC)

The RediGate is classified as a component with regard to FCC EMC regulations, and it is the user’s

responsibility to ensure that systems using the product are compliant with the appropriate EMC

standards.

This equipment has been tested and found to comply with the limits for a Class A digital device,

pursuant to part 15 of the FCC Rules. These limits are designed to provide reasonable protection

against harmful interference when the equipment is operated in a commercial environment. This

equipment generates, uses, and can radiate radio frequency energy and, if not installed and used in

accordance with the instruction manual, may cause harmful interference to radio communications.

Operation of this equipment in a residential area is likely to cause harmful interference in which case

the user will be required to correct the interference at his own expense.

2.4.1 Radio Frequency Requirements

This device complies with Part 15 of FCC Rules. Operation is subject to the following two conditions:

1. This device may not cause harmful interference.

2. This device must accept any interference received, including interference that may cause

undesired operation.

3. To comply with RF safety requirements, you must maintain a distance of 20 cm from the

antenna when operating the device.

4. Each antenna of this device must not be co-located within 20 cm of any other antenna or

transmitter. Antenna requirements are listed in Cellular and GPS Antennas on page 24.

The RediGate 400 may be supplied with an EVDO cellular module (FCC ID: RI7DE910-DUAL), or

with a GSM cellular module (FCC ID: RI7HE910).


Changes or modifications to the product not expressly approved by Elecsys Corporation could void

the user’s authority to operate the equipment.

2.5 Disclaimers

The information in this manual is believed to be accurate at the time of publication. Elecsys

Corporation assumes no responsibility for inaccuracies that may be contained in this document and

makes no commitment to update or keep current the information contained in this manual.

Elecsys Corporation assumes no responsibility for any infringements of patents or other rights of

third parties that may result from its use.

Elecsys Corporation reserves the right to make changes or improvements to this document and/or

product at any time and without notice.

WARNING: DO NOT CONNECT OR DISCONNECT CABLES WHEN

ENERGIZED, UNLESS POWER HAS BEEN REMOVED FROM THE EQUIPMENT

OR THE AREA IS KNOWN TO BE FREE OF IGNITABLE CONCENTRATIONS OF

FLAMMABLE SUBSTANCES.


3 Introduction The RediGate is a ruggedized field proven edge-of-network front end processor designed for

industrial field applications. This single device enables a seamless migration path for quicker data

acquisition, automatic communication failover, cyber security, bandwidth management, and protocol

conversion throughout your entire industrial communication network.

With a wide selection of industry standard and legacy protocols, the RediGate can gather data from

almost any field device and deliver it to your enterprise data systems. Combining our Advanced

Configuration Environment (ACE) with one of the industry’s best application programming languages

(ISaGRAF), the RediGate can be easily programmed for most applications.

The RediGate 400 Series has an optional integrated cellular modem and also supports I/O

expansion options enabling the unit to be easily customized for your specific application. Utilizing its

native MQTT client, the RediGate directly interfaces with messaging middleware/data brokers, new

and legacy SCADA hosts, ERP systems, Leak Detection, Maintenance Systems and other

enterprise applications. Elecsys also provides the “HCP2” (host communication processer) and OPC

software packages to enhance the performance and capabilities of your existing system.

This manual provides information describing the hardware for the Elecsys RediGate 400 Series

Industrial Data Gateway. It details the standard and optional hardware components, technical

specifications, and other hardware information that may be needed to configure the device. The

RediGate is based upon a Linux based operating system.

All circuit boards are mounted in a rugged metal enclosure. RediGate units are shipped fully tested

and may be pre-loaded with customer-specific configurations prior to shipment.

3.1 RediGate 400 Model Options

The RediGate 400 Series Gateways have a variety of hardware and software options depending on

the model chosen. Some of these optional features are described below:

EVDO modem Internal EVDO cellular modem (Verizon)

GSM modem Internal GSM/HSPA cellular modem (AT&T, Telus)

4 COM ports Additional RS-232 and RS-485/422 serial ports (total of 6 RS-232, 2 RS-485)

Multi-I/O Internal I/O expansion board, providing 16 AI, 2 AO, and 8 DI

Relay8/IN8 Internal I/O expansion board, providing 8 DI and 8 relay outputs

Please contact Elecsys to obtain pricing for a particular configuration of optional equipment or

software. The table below gives model numbers for several standard part numbers of the base

RediGate plus combinations of optional features. All models typically use COM0 (RS-232) for the

administrative console port.


Examples: RG-400e-00-00 Base RediGate 400 (4 Ethernet, 2 RS-232, 1 RS-485/422

RG-400c-22-00 RediGate 400 + GSM/HSPA modem, customer installed SIM

RG-400e-00-12-C RediGate 400 + Multi-I/O + Relay8/IN8 + custom software

3.2 Accessory Options

Elecsys provides several accessories for use with the RediGate. Please contact Elecsys to obtain

pricing and model numbers for accessory equipment.

RediGate Accessories

Power Supply Standard – Cable only for connection to power source

Optional – 110V power supply with 12VDC output

DIN Rail Mounting Kit Kit for mounting enclosure to a standard DIN rail

Data Modem Elecsys E-Modem cellular data modem

COM 4 4-port serial interface expansion board

Multi-I/O 16 Channel ADC, DAC and digital I/O expansion board

Expansion board Kits Additional expansion options are available

RG – 400 x – x x – x x – C

RediGate 400

COM options

e = Ethernet only (no cellular)

c = Optional cellular modem

Cellular Modem options

0 = No cellular

1 = Verizon EVDO modem

2 = GSM/HSPA modem

Custom software (optional)

C = Factory loaded customer

configuration / software

Slot #2 I/O Options

(same as Slot #1 options 0-2)

Slot #1 I/O Options

0 = None

1 = Multi-I/O

2 = Relay8/IN8

3 = 4 serial ports

Cellular SIM options

0 = No SIM

1 = Factory installed SIM

2 = GSM cellular,

customer installed SIM


4 Specifications

4.1 Enclosure / Dimensions

Model RediGate 400

Width 6.92” (175.77 mm)

Depth 6.78“ (172.21 mm)

Height 2.61” (66.29 mm)

Weight

(excluding optional equipment) 2.5 lbs (1.13 kg)

4.1.1 Dimensions

The mechanical and mounting dimensions of the RediGate are shown below (all dimensions in

inches).

Top


Bottom

Front RediGate 400


Rear RediGate 400

with optional modem

Rear RediGate 400

with optional modem and 4 serial

Rear RediGate 400

with optional modem, serial, and I/O

[Drawing TBD]

4.1.2 Mounting Instructions

The RediGate is intended to be installed in a Restricted Access Location. When mounting the

RediGate, allow sufficient space to connect the cables on the front and rear of the enclosure,

depending on any optional hardware components installed. There are two recommended means of

mounting the device: panel mount, or DIN rail mount.

For panel mounting the RediGate, use four screws of an appropriate size and type to securely attach

the enclosure to a customer-supplied panel or enclosure, using the four keyhole slots on the sides of


the mounting plate bracket shown in the dimensional diagrams in the previous section. Connect all

the I/O cables, and lastly attach the power connector to the RediGate.

The RediGate are optionally supplied with two (2) DIN rail clamps (shown on the bottom view

dimensional drawing in the previous section). The DIN rail clamps allow mounting either vertically or

horizontally. To mount the RediGate to DIN rail, use the following instructions:

1. Determine the correct location and orientation of the RediGate that will accommodate all

attached cables and connectors.

2. Install a piece of DIN rail (35mm top hat rail) to the mounting location using appropriate

screws or bolts. DIN rail should be installed horizontally, and should be a minimum of 5 in.

(127mm) for mounting the RediGate in the vertical orientation, or a minimum of 10 in. (254

mm) for mounting in the horizontal orientation.

3. Detach the mounting plate bracket from the RediGate by removing the four screws.

4. On the other side of the mounting plate bracket (the side touching the RediGate enclosure)

there are eight countersunk screw holes. Only four of these screw holes will be used,

depending on the intended mounting orientation of the RediGate.

5. Using the four supplied DIN rail clamp screws (M4, 6mm), attach the two DIN rail clamps to

the mounting plate in either the horizontal or vertical orientation, as determined earlier.

Vertical orientation Horizontal Orientation

6. Reattach the mounting plate bracket to the RediGate using the original screws (8-32, 3/8 in).

7. Hang the spring side of the RediGate’s DIN rail clamps on the DIN rail and snap into place.

8. Ensure that the mounting is secure, then connect all the I/O cables, and lastly attach the

power connector to the RediGate.

4.1.3 Compliance with Hazardous Area Standards

The RediGate has approval for installation in Class I Division 2 Groups A, B, C and D Classified

Hazardous Locations, temperature class T4. Class, Division, and Group are defined as:


• Class defines the general nature of the hazardous material in the surrounding atmosphere. Class

I is for locations where flammable gases or vapors may be present in the air in quantities

sufficient to produce explosive or ignitable mixtures.

• Division defines the probability of hazardous material being present in an ignitable concentration

in the surrounding atmosphere. Division 1 locations are presumed to be hazardous. Division 2

locations are areas where gas, dust, or vapors can exist under abnormal conditions.

• Group defines the hazardous material in the surrounding atmosphere. Groups A to D are defined

as follows:

• Group A – Atmosphere containing acetylene, gases or vapors of equivalent hazards.

• Group B – Atmosphere containing hydrogen, gases, or vapors of equivalent hazards.

• Group C – Atmosphere containing ethylene, gases, or vapors of equivalent hazards.

• Group D – Atmosphere containing propane, gases, or vapors of equivalent hazards.

For the RediGate to be approved for hazardous locations, it must be installed according to the

National Electrical Code (NEC) Article 501 (or Canadian Electrical Code, Section 18), and any local

code requirements, if applicable.





When installing units in a hazardous area, make sure all installation

components selected are labeled for use in such areas. Installation and

maintenance must be performed only when the area is known to be non-

hazardous. Installation or maintenance in a hazardous area could result in

personal injury or property damage.

The certificate for this equipment includes the following special conditions for safe use:

1. Install the equipment in an IP54 or better enclosure or equivalent location. Any enclosure

shall be suitably certified or otherwise approved for Class 1 Division 2 hazardous locations.

This may include an instrumentation tray cable (Type ITC) or similar means of limiting access

to connect or disconnect cables under hazardous conditions.

2. Ensure that the rated input voltage is not exceeded in service.

3. The USB ports should not be used in a hazardous location.


4.2 System Specifications

4.2.1 General Features:

Model: RediGate 400

Memory: RAM: 256MB

Flash: 64MB

Serial Ports: 3x RS-232 (up to 6x with expansion)

1x RS-485/422 (up to 2x with expansion)

LAN: 4x RJ45 10/100baseT

USB Ports: 2x USB 2.0 host ports

4.2.2 Power





Operational Voltage: +9.5 to +28 V , 1.5 A max.

Overvoltage Protection: +50 V maximum

Reverse Voltage Protection: -28 V maximum

Operating Current @24V: 121 mA nominal

Power Consumption: *

Base RediGate 400:

Base + modem: *power excludes USB (normally unused)

and optional I/O cards

Nominal Max

3.5 W 5 W

4 W 6 W

– The device is intended to be powered from a Certified Limited Power Source (LPS, as defined in standard 60950-1) or a Certified “Class 2” Power Source (as defined in NEC and CEC).


4.2.3 Environmental Characteristics

Operating: -40 to +75 °C

Storage: -40 to +125 °C

Humidity: 0% to 95% relative humidity (non-condensing)


5 Base RediGate 400 Hardware This section describes the standard hardware and provides the dimensions and technical

specifications for the RediGate. RediGate units are shipped fully tested and are typically supplied

containing a default software configuration. Certain units may be pre-loaded with customer-specific

configurations prior to shipment.

The RediGate consists of the following hardware components:

• Enclosure – Metal housing that contains the circuit boards and provides mounting options

• Data I/O Ports – Ethernet and serial COM ports used for peripheral communications

• Power Input – Connection port for powering the unit

• Status LEDs – Indicates process operations and functionality

• Top – Flashes and increases speed as the system load increases

• Center – Flashes to indicate that the system software is operational (watchdog enabled)

• Bottom –

5.1 Ethernet Ports

The RediGate provides 10/100 Mbps Ethernet ports for network communications, labeled ‘0’, ‘1’, ‘2’

and ‘3’. In Linux, these correspond to network interfaces ‘eth0’ through ‘eth3’, respectively. Each of

the Ethernet interfaces must be configured using the Advanced Configuration Environment (ACE)

software tool in order to function, either with a fixed IP address or dynamically assigned DHCP

addressing. The ports should be configured to operate on different, non-overlapping IP

addresses/subnets.

Ethernet ports do not provide Power over Ethernet (PoE) and should not be connected to an

unregulated PoE device.

Ethernet ports not suitable for direct connection to WAN unless an appropriate interface is

provided, to ensure lightning surge protection.






5.2 Serial Ports

The base RediGate comes equipped with four external serial ports (3 RS-232, 1 RS-485/RS-422),

with an option for four additional ports (total of 6 RS-232, 2 RS-485/RS-422). These ports are

intended for local configuration and programming and for connection to external field devices.

The serial ports are configured using the ACE software tool. The first serial port (COM0) is typically

reserved for a serial diagnostics, configuration and maintenance port.

The built-in serial ports are identified in Linux as follows:

Port Linux Device Electrical Standard

COM0 /dev/ttyS0 RS232

COM1 /dev/acscomm1 RS232


COM3 /dev/acscomm3 RS-485/422




COM7 /dev/acscomm7 RS-485/422





5.2.1 RS-232 Serial Interfaces

The direction of data with respect to the RediGate serial interfaces is such that the RediGate acts as

a DTE (Data Terminal Equipment) device. The pin-out of the DB-9 serial interface for the RediGate

RS-232 ports is as follows:


DB-9 Male

1 2 3 4 5

6 7 8 9

Pin EIA-232

Name Type Description

1 DCD Input Data Carrier Detect

2 RXD Input Receive data

3 TXD Output Transmit data

4 DTR Output Data Terminal Ready

5 GND Common Ground

6 DSR Input Data Set Ready

7 RTS Output Request To Send

8 CTS Input Clear To Send

9 RI Input Ring Indicate

When configuring the RS-232 ports using the ACE software tool, the Warm-up and Warm-down

fields are optional parameters that can be used to enable hardware flow control. This may be

required to control sending and/or receiving data through certain external devices such as modems.

If hardware flow control is not required, both the Warm-up and Warm-down parameters should be

set to “-1” to disable hardware flow control.

5.2.2 RS-485/RS-422 Serial Interfaces

The RediGate provides an external RS-485/422 port on COM3, and optionally on COM7.

NOTE: When configuring the RS-485/422 ports using the ACE software tool, the Warm-up

and Warm-down times must be set to “0”. This enables hardware flow control, which is

required to control the internal RS-485 circuit.

RS-485/422 uses an optically isolated, balanced differential system, in which the voltage produced

by the driver appears across a pair of signal lines that transmit a single signal. A balanced line

driver produces a voltage from 2 to 6 volts across its positive and negative output terminals. A

balanced differential line receiver senses the voltage state of the transmission line across the two

signal input lines. Up to 32 RS-485 devices or 10 RS-422 devices can be connected together in a

multi-drop configuration.

The RediGate uses a four-wire serial interface for RS-485/422. The DB-9 pin-out is identified as

follows:


DB-9 Male

1 2 3 4 5

6 7 8 9

Pin RS-485

Name Type Description

1 NC

2 NC

3 TX- Output Transmit Data -

4 RX- Input Receive Data -

5 GND Common Ground

6 NC

7 TX+ Output Transmit Data +

8 RX+ Input Receive Data +

9 NC

5.2.3 RS-485/422 Wiring Diagrams

When connecting RS-485 or RS-422 devices in a multi-drop configuration, there should typically be

a 120Ω termination resistor at both devices located at the ends of the network, but not on devices

located in the middle of the network. This is used to balance the impedance in a long transmission

line.

The RS-422 interface provides full-duplex communication. It supports one transmitter and up to 10

receivers.

The 4-wire RS-485 interface can provide either half-duplex or full-duplex communication. The

interface supports up to 32 transmitters and receivers on a single network. Only one transmitter

should be switched on at a time.

Some RS-485 devices use a 2-wire communication port instead of 4-wire. In order to connect the

RediGate’s RS-485 port to a 2-wire RS-485 device, connect the positive terminals (TX+ & RX+) to

the positive terminal of the other device(s), and connect the RediGate’s negative terminals (TX- &

RX-) to the negative terminal of the other device(s). The ‘customer’ file must be set to ignore echo

(see the RediGate Configuration Manual).

In RS-485 or RS-422 systems, the ground connection is required to properly establish the voltage

reference for the differential voltages of the transmit and receive lines. The maximum end-to-end

cable length for an RS-485/422 network is rated at 1200 m (4000 ft). Care should be taken in long

runs to use twisted, shielded pair wiring to avoid the introduction of electromagnetic noise on the

communication lines.


Typical RS-485 and RS-422 connections are shown in the following figure. Multi-drop networks are

designed to be wired in a daisy-chain arrangement as shown, rather than a star arrangement

(multiple nodes connected to a single point).

TX+

TX-

RX+

RX-Gnd TX+

TX-

RX+

RX-Gnd TX+

TX-

RX+

RX-Gnd

4-wire RS-485/422 Device Connections

Master Device Middle Device(s) End Device

Data+ Data- Gnd Gnd Gnd

2-wire RS-485 Device Connections


Data+ Data- Data+ Data-

Gnd Gnd GndData+ Data- Data+ Data-

4-wire to 2-wire RS-485 Device Connections


TX+

TX-

RX+

RX-


5.3 Real-time Clock

The RediGate includes a real-time clock, which may be used in some software features, such as

system log files. There is no battery backup for the real-time clock, so if the clock is important to a

particular application, the time must be synchronized after power-up to a network time server with

Network Time Protocol (NTP). NTP may be configured using the ACE configuration software.


6 Optional RediGate 400 Hardware Certain models of RediGate provide for optional hardware components. These optional components

include:

• Additional Serial Ports – Additional four serial ports (3 RS-232, 1 RS-485).

• Cellular Modem – An EVDO or GSM/HSPA modem for cellular network connection

• Multi-I/O – I/O module providing 8 digital inputs, 16 analog inputs, and 2 analog outputs

• Relay8/IN8 – I/O module providing 8 digital inputs and 8 Form C relay outputs

6.1 Serial Port Expansion

The RediGate may be supplied with an optional 4 serial ports. See Serial Ports on page 18 for

details and pinouts of the additional ports.

6.2 Cellular Modem

Certain models of RediGate provide a modem for cellular network communications. Only one

modem may be used, depending on the chosen type of wireless technology. The modem is factory

installed in the RediGate, and external antenna jacks allow connection to cellular (SMA) and GPS

(MCX) antennas.

The EVDO socket modem card is based on the Telit DE910-DUAL wireless module and provides

dual band CDMA/1xRTT EVDO wireless support. The modem is certified for use on the Verizon

cellular network.

The GSM socket modem card is based on the Telit HE910 wireless module and provides multi-band

GSM/GPRS/EDGE/UMTS/HSPA+ wireless support. The modem is certified for use on the AT&T

cellular network in the United States, and the Telus cellular network in Canada.

The choice of modem may depend on the quality or availability of cellular service at the intended

location for device installation.

6.2.1 Cellular Account Activation

In order to use the RediGate with a cellular modem, each device must be included on an active data

plan with the cellular carrier. If the application requires inbound (mobile-terminated) connections to

the RediGate, it may be necessary to have a public, static IP address, which is typically an optional,

billable feature of the cellular service. For enhanced security, it may be desired rather to activate

cellular service on a private network (APN/VPN) with static IP addresses.


6.2.2 Cellular and GPS Antennas

The RediGate with cellular modem and GPS requires an external cellular antenna and/or GPS

antenna. The antenna should be chosen with the correct frequency band, connector, cable length,

and appropriate mounting type. Some antennas provide an integrated cellular transceiver and GPS

receiver, but these are not recommended.

The cellular connector requires an antenna with a standard male SMA plug and 50 ohm cable, with

a minimum cable length of 20 cm and maximum gain (including cable loss) as follows:

Frequency EVDO GSM

824-846 MHz 5.12 dBi 5.22 dBi

1712-1752 MHz n/a 3.31 dBi

1851-1907 MHz 6.12 dBi 6.45 dBi

The GPS connector requires an antenna with a standard male MCX plug and 50 ohm cable with

frequency 1575.42 MHz. The use of an active GPS antenna may achieve better performance,

especially when the GPS antenna distance from the device is quite high.

6.3 MULTI-I/O Board

Certain models of RediGate provide an analog/digital module, allowing the RediGate to be used for

data acquisition from up to 16 analog inputs, 8 digital inputs, and 2 analog outputs. The Multi-I/O

module (Eurotech model AIM104-MULTI I/O) is factory installed inside the RediGate. A 50-way ‘D’

type connector allows connection to the field signals using an external screw termination block.

6.3.1 Multi-I/O Specifications

Power Consumption 2.4 Watts, excluding loop power

Link settings Analog Mode

Board #1 address

Board #2 address

16 channel AI single-ended (LK3 fitted, LK4-A)

LK1 jumpers: A2, A3, A4, A6 [0x3A0]

LK1 jumpers: A3, A4, A6 [0x3A4]


Digital Inputs

Number of inputs

8 opto-isolated digital inputs

(provides 0-4MHz counter input as well as binary

status, negative edge triggered, not clearable)

Switching Voltage Range 10 V to 30 V

Maximum Input Frequency 50 Hz

Isolation 1000 V to field

30 V between adjacent channels

Protection Reverse protection diodes

Analog Inputs

Number of inputs 16 single-ended (non-isolated)

Voltage/current range

0 to 5 Vdc (0 to 20 mA with external 250Ω)



0.8 to 4 Vdc (4 to 20 mA with external 200Ω)

Input range depends on software configuration

(ISaGRAF, POD)

Resolution 12 bits

Opto-isolation 1000 V to field


Input Impedance 10 MΩ, 10 pF typical

Relative Accuracy ±2 LSB (max) @ 25ºC

Analog Outputs

Number of outputs 2

Voltage/Current Range Options 0 to 20 mA

0 to 5 Vdc

Resolution 12 bits



Output Impedance Vout =< 10Ω

Accuracy ±2 LSB (max) @ 25ºC


6.3.2 Multi-I/O Wiring





When an optional Multi-I/O board is included with the RediGate 400, it is typically made available on

the rear of the enclosure using a 50-way ‘D’ type connector. An interconnecting ‘D’ male-male cable

and 50-way DIN rail mountable screw termination block are supplied for easy access to field wiring.

These accessories are identified with the following part numbers:

Termination block – Elecsys stock code #15-2315-50 (such as Phoenix Contact p/n 2315201)

50-way cable – Elecsys stock code #47-0060-50 (such as L-COM p/n CSMN50MM-2.5)

NOTE: When making connection to field I/O, note that the 50-way ‘D’ type connector on the

rear of the RediGate 400 has a different pin numbering from the interconnecting cable and

screw termination block. See the following table.

The following table lists the I/O function, pin designations, and screw terminal numbers on the

external termination block.

Function (MULTI-I/O) 50-way ‘D’ pin

(enclosure)

50-way screw

termination

Digital Inputs

DI Common 1 1

DI 1 2 34

DI 2 3 18

DI 3 4 2

DI 4 5 35

DI 5 6 19

50-way 'D'(enclosure)

50-way 'D' cable (M-M)

50-way screw termination


DI 6 7 3

DI 7 8 36

DI 8 9 20

DI Common 10 4

Analog Inputs

AI Common 20 40

AI 1 12 21

AI 2 13 5

AI 3 14 38

AI 4 15 22

AI 5 16 6

AI 6 17 39

AI 7 18 23

AI 8 19 7

AI 9 22 8

AI 10 23 41

AI 11 24 25

AI 12 25 9

AI 13 26 42

AI 14 27 26

AI 15 28 10

AI 16 29 43

AI Common 30 27

Analog Outputs

Current output:

AO 1 Current Loop 34 12

AO 1 Current Return 36 29

AO 2 Current Loop 38 46

AO 2 Current Return 40 14

Voltage output:

AO 1 Vout 43 15

CGND 35 45

AO 2 Vout 44 48

CGND 39 30

(unused CGND pins) 11, 21, 31 37, 24, 11

(not connected) 32, 33, 37, 41,

42, 45, 46, 47,

48, 49, 50

44, 28, 13,

47, 31, 32,

16, 49, 33,

17, 50


Some typical wiring diagrams are shown below. Ensure that connections are made to the

appropriate termination number for each input or output type, and that the configuration is set

correctly for the board number and analog input type (see Multi-I/O Software Access).

6.3.3 Multi-I/O Software Access

To read the analog or digital inputs and write to the analog outputs, use either ACE-defined POD

logic (“PC-104 MULTI-IO-se” function) or an ISaGRAF program (include the “AIMMLTIO” board). In

either case, the board parameters should include the Board Address (see Multi-I/O Specifications),

and the data should be made available in appropriate RTDB addresses.

The following screen capture is an example of POD logic using the Multi-I/O board. The Operand

for the PC-104 MULTI-IO-16se function is “x3A0” to represent the Board #1 address as

hexadecimal. Analog input data is stored starting from the 2nd register (e.g. 30002-30017), and

analog outputs are written from the Source Addr (e.g. 40001-40002). The BIT-UNPACK function is

optional and may be used to move the bits (e.g. addresses 10001-10008) out of the packed analog

RTDB registers (e.g., 30001). The last four registers (e.g. 30018-30022) store low-speed counters

for the first four digital inputs, up to about 10 Hertz. See the POD Programming Manual for more

information on using POD logic.

When writing to analog outputs using the PC-104 MULTI-IO-16se POD function, values 0 to 4095

represent voltages of -5 to +5 volts. Analog input values using the POD function represent voltages

0 to +5V as integer values 0 to 4095.

Digital input wiring

DI #

DI Common

+ Switching - voltage

Analog input wiring (current)

AI #

AI Common

Current Source (0-20 or 4-20 mA)

250 ohm (external)

Analog input wiring (voltage)

AI #

AI Common

+ Input voltage - (0-5 or 1-5)

Analog output wiring (current sink)

Current Loop

Current Return

+Supply voltage -

isolated ground

200 ohm

load resistor Analog output wiring (voltage)

AO # Vout

CGND

+ Output - voltage(0-5, 1-5, -5 to +5)


The following screen captures are an example of the I/O connection in ISaGRAF when using the

Multi-I/O board. Analog and digital input values are stored in the ISaGRAF RTU and must be polled

into an RTDB using the Internal Channel configuration, so that data can be made available to other

systems. Analog outputs must be written to the ISaGRAF RTU.

The “Scale” parameter for the analog inputs (mult16ai) determines the scale for the registers values

read in the range of 0-4095. The Scale should be set as follows:

0 0-5 volts = 0-20 mA through 250 ohm resistor



3 0.8-4 volts = 4-20 mA through 200 ohm resistor

The “Scale” parameter for the analog outputs (mult2ao) determines the scale for register values

written in the range of 0-4095 to control outputs. The Scale should be set as follows:

0 0-5 volts = 0-20 mA through 250 ohm load

1 1-5 volts = 4-20 mA through 250 ohm load


6.4 Relay8/IN8 Board

Certain models of RediGate provide a digital I/O module, allowing the RediGate to be used for data

acquisition from up to 8 digital inputs and 8 Form C relay outputs. The Relay8/IN8 module

(Eurotech model AIM104-RLY8/IN8) is factory installed inside the RediGate. A 50-way ‘D’ type

connector allows connection to the field signals using an external screw termination block.

6.4.1 Relay8/IN8 Specifications

Power Consumption 1.25 Watts, excluding loop power

Link settings Board #1 address

Board #2 address

Input filter (de-bounce)

LK1 jumpers: A2, A3, A4, A7 [0x360]

LK1 jumpers: A3, A4, A7 [0x364]

LK2A-H fitted


Digital Inputs

Number of inputs 8 opto-isolated digital inputs

Switching Voltage Range 10 V to 30 V

Maximum Input Frequency 50 Hz with de-bounce filter enabled

10 KHz with de-bounce filter disabled



Protection

Reverse protection diodes

±40 V steady state overvoltage

300 W surge for 1 ms

Digital Outputs

Number of outputs 8 Form C relay outputs

Normally Open and Normally Closed contacts

Switching Range

Voltages up to 48 V and currents up to 1.0 A

Power switching rating of 60 W (resistive load)

Relays de-energize on power up/reset



6.4.2 Relay8/IN8 Wiring





When an optional Relay8/IN8 board is included with the RediGate 400, it is typically made available

on the rear of the enclosure using a 50-way ‘D’ type connector. An interconnecting ‘D’ male-male

cable and 50-way DIN rail mountable screw termination block are supplied for easy access to field

wiring. These accessories are identified with the following part numbers:

Termination block – Elecsys stock code #15-2315-50 (such as Phoenix Contact p/n 2315201)

50-way cable – Elecsys stock code #47-0060-50 (such as L-COM p/n CSMN50MM-2.5)


NOTE: When making connection to field I/O, note that the 50-way ‘D’ type connector on the

rear of the RediGate 400 has a different pin numbering from the interconnecting cable and

screw termination block. See the following table.

The following table lists the I/O function, pin designations, and screw terminal numbers on the

external termination block.

Function (RELAY8/IN8) 50-way ‘D’

(enclosure)

50-way screw

termination

Digital Inputs

DI Common 1 1

DI 1 2 34

DI 2 3 18

DI 3 4 2

DI 4 5 35

DI 5 6 19

DI 6 7 3

DI 7 8 36

DI 8 9 20

DI Common 10 4

Digital Outputs

Relay 1 Common 12 21

Relay 1 Normally Open 13 5

Relay 1 Normally Closed 14 38




Relay 3 Common 22 8







50-way 'D'(enclosure)

50-way 'D' cable (M-M)

50-way screw termination













(not connected) 11, 15, 16,

20, 21, 25,

26, 30, 31,

35, 36, 40,

41, 45, 46,

50

37, 22, 6,

40, 24, 9,

42, 27, 11,

45, 29, 14,

47, 32, 16,

50

Some typical wiring diagrams are shown below. Ensure that connections are made to the

appropriate termination number for each input or output type, and that the configuration is set

correctly for the board number and analog input type (see Relay8/IN8 Software Access).

6.4.3 Relay8/IN8 Software Access

To read the digital inputs and write to the digital outputs, use either ACE-defined POD logic (“PC-

104 IN-8” and “PC-104 OUT-8” functions) or an ISaGRAF program (include the “AIMRELAY” board).

In either case, the board parameters should include the Board Address (see Relay8/IN8

Specifications), and the data should be made available in appropriate RTDB addresses.

The following screen capture is an example of POD logic using the Relay8/IN8 board. The Operand

for the PC-104 IN8 and PC-104 OUT8 functions is “x360” to represent the Board #1 address as

hexadecimal. The BIT-PACK and BIT-UNPACK functions are optional and may be used to move the

bits (e.g. addresses 1-8 and 10001-10008) into and out of packed analog RTDB registers (e.g.,

30001, 40001). See the POD Programming Manual for more information on using POD logic.

Digital input wiring

DI #

DI Common

+ Switching - voltage

Relay output wiring

Normally closed

Normally open

Common


The following screen captures are an example of the I/O connection in ISaGRAF when using the

Relay8/IN8 board. Digital input and output values are stored in the ISaGRAF RTU and must be

polled into an RTDB using the Internal Channel configuration, so that data can be made available to

other systems.

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