Hardware manual - Remote Processing
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1. Read or write Relay on off set as bits 0 7 Write one word to control all 8 relays at the same time A 1 turns on a relay O turns it off Read only Status of opto buffered input 1 IN Read only Status of opto buffered input 2 IN 1 2 3 Read or write Relay 7 on off 1 relay On O relay Off Read or write Relay 8 on off 1 relay On 0 relay Off COI gt Appendix A Modbus Map Page 5 Appendix A CX 10 Modbus Map Watchdog Timer These are all integer 16 bit types Function code 3 reads 16 writes Register_ Read Write Permission Detail 2222 Read or write Watchdog timeout value 0 disable watchdog 1 255 Timeout seconds 31 Read or write Watchdog timer value This register increments every second until it matches the value in Register 30 or until a 0 is written to this register Non Volatile Intgeger storage These are integer 16 bit types Function code 3 reads 16 writes Address range is 4001 to 4256 inclusive These registers retain data when power is removed from the board These registers may be set to 0 by writing a 0 to register 4802 and resetting the board Note that writing a O to 4802 also clears floating point non volatile registers Volatile Integer storage These are integer 16 bit types Function code 3 reads 16 writes Address range is 4501 to 4628 These registers reset to O on power up or CPU reset manual or watchdog timeout Appendix A Modbus Map Page 6 Appendix A CX 102. Write Func 16 button If all is OK 3 relays should click 3 LED s on the CX 10 board should be illuminated You can individually control relays and monitor specific opto inputs For more information refer to Relay control section to control and read relays Refer to Opto Inputs seconds to read opto input status A complete Modbus register map is in Appendix A Registers used for specific IO are listed in each chapter BASIC OPERATION You will need a serial terminal program such as Windows Terminal Hyperlink TerraTerm or RPTERM RPTERM is on your CD or may be downloaded at our website at www rp3 com downloads Connect the VTC 9 serial cable to the programming port as shown above in Figure 2 1 Note that the key notch on the VTC 9 cable faces to the inside of the board Set your terminal communication parameters as follows Baud rate 19200 Data bits 8 Parity None Stop bits 1 Connect the serial ports Connect the DB 9 end to the PC s COM port This is determined from Serial Port Setup above Power up Turn on or connect the power supply if you have not done so already MCS 51 tm BASIC V2 0 Version CX 10 Portions Copyright c 2008 Control Design and c 2009 Remote Processing Corp Build Jan 29 2009 10 04 51 The above message should appear If a nonsense message appears your terminal or PC may not be set Page 2 6 SECTION 2 to the appropriate communication parameters
3. 0 shutdown off 4826 Read or write Opto buffered input LED enable 1 enable default 0 disable 4827 Read or write Battery charge voltage control 0 low rate default approximately 14V 1 high rate approximately 15V 4828 4999 _ No read write allowed High Speed Counters Two high speed counters are available at IN7 and IN8 Read Write Permission 7001 Pulse counter 1 on A oo 7002 Read and Write a O counter 2 on IN7 Both counters count from 0 to 16 777 215 Maximum count rate is 3Khz 180 000 pulses minute with a 0 12V signal to INS or IN7 Pulse counters are reset by writing 0 to them Non Volatile Floating Point Storage Registers 7101 to 7356 store 32 bit floating point numbers Non volatile storage has 1 000 000 write limitation Appendix A Modbus Map Page 11
4. For example suppose you needed relays 1 3 and 7 turned on Register 10 value is computed as register_value 1 4 64 69 Writing a value of 69 register 10 will energize relays 1 3 and 7 This would have the same effect as writing a 1 to registers 19 22 and 25 Using Basic the command becomes 50 REGWRITE 10 69 The status of each relay may be read by polling the appropriate register Register 10 returns the status of each relay in one number In Basic this may be done as 100 A REGREAD 10 Assuming 69 was written to register 10 variable A should return a value of 69 RELA Y AND OPTO INPUT LINES Opto Buffered Inputs Opto inputs are designated on the CX 10 board as IN1 INS Common grounds are available on P2 and P4 See Figure 6 4 above for location Below is a table of input designations and corresponding modbus register number Also given are register 1 weight values for inputs Input Modbus Register 1 Register 1 designatio register bit position weight n value IN1 11 1 1 IN2 12 2 2 IN3 13 3 4 IN4 14 4 8 INS 15 5 16 IN6 16 6 32 IN7 17 7 64 IN8 18 8 128 Modbus register 1 returns the status of all 8 inputs as one number This may be useful in a Basic program where bit testing is more expedient than accessing individual registers Page 6 4 SECTION 6 For example suppose on levels are required at IN1 and IN5 to turn off relays Basic code could be written as 100 A REGREAD 1 110
5. Source address 7975 GPO01 configuration RS485 TX active high The lower RF baud rate allows for further distances The unique addresses prevent other similar devices from interfering with other similar 900 Mhz modems Using the RF modem limits modbus packet sizes A maximum of 122 integers and 61 float registers may be sent received at any one time RF Modem Power ON OFF control The RF modem power may be turned on or off through register 4825 A 1 written turns on the modem ON is default A O written to this register turns off the modem This is a non volatile register meaning its state is stored in EEPROM and will retain the last programmed state on power up or reset Turning off the modem saves about 90 milli amperes BASIC Page 4 6 SECTION 4 ACCESSING SERIAL BUFFERS Access COMO and COM3 buffers in Basic by using the GET n function This function only works for COM 0 when COM3 is configured for modbus operation If COM 3 is in ASCII mode use GET 3 to retrieve data If there is no data in the COMO or COM 3 port a value of 256 is returned When COM 3 is in modbus mode the only way to access data in the buffer is when COM 3 is running a Basic program and is in master mode Master mode is automatically entered using the PRINT 3 command Buffer data variants are retrieved using register 4782 See registers 4781 4783 for more information DISABLING CONTROL C Program execution is terminated by entering a
6. To do this review the program in the Basic Demo directory under the name download header bas You can copy this code and put it at the start of yours Essentially this program has the start and end of your program When you download code the commands will automatically take care of housekeeping You may have trouble downloading long programs depending upon your terminal Ideally your terminal program should recognize a lt CR gt gt sequence before sending the next line Terminal programs such as Terra term or Hyperterm do not do this To reliably download long programs insert a 100 milli second delay between each line transmitted This may or may not be in your terminal program For Terraterm click on Setup in the top banner then click on Serial Port You will get a window prompting you for port baud rate set to19200 parity none stop bits 1 and flow control none At the bottom set transmit delay to 1 for msec char and 100 for msec line A program named Download core bas in the Basic SETUP AND OPERATION MODBUS and BASIC Demo directory is an example of automated download process This program clears out the old program and prepares for a new one Programming Commands The following programming commands are used on the CX 10 For some part they follow the original Basic 52 structure However there are some differences due to the nature of the flash in the CPU For example baud rat
7. means it must be able to supply 5 milli amperes of current Pulse counters are read in registers 7001 and 7002 These registers are available over modbus and in Basic In Basic this is done using the REGREAD function Maximum count is 16 777 215 The counter will then roll over and start at 0 again SECTION 7 Pulse counters reset to 0 when the board is first powered up or reset They do not have memory Counters may be set to 0 or preset with any number up to 65535 by writing to the register In Basic this is done using the REGWRITE command Under special conditions pulse rate may be as high as 17Khz Consult factory for details APPLICATION PROGRAMS The following program is in the Basic Demos directory Function Page 7 5 7001 counter demo bas Shows use of register 7001 BATTERY CHARGER amp POWER INTRODUCTION The CX 10 requires a minimum of 12 volts to operate Power may be from a line powered DC supply 1 ampere or solar panel and lead acid battery The CX 10 incorporates a temperature compensated battery charging circuit The circuit is designed to charge a lead acid type battery Battery voltage and switched battery voltage are available at P2 BATTERY CHARGER Two charging rates are possible through register 4827 A lower voltage float charge and a higher voltage charge The following table shows the theoretical charging voltages at different temperatures Temperature Float Cha
8. IF A AND 17 17 THEN REGWRITE 10 0 The value of 17 is computed by adding IN1 and IN5 weight values of 1 and 16 The AND operation filters out inputs that are of no interest for this test Sometimes it is expedient to monitor just one line Suppose input IN2 monitors an alarm condition such as high water You may want to close the gates in this situation 200 IF REGREAD 12 1 THEN GOSUB 2000 The routine at line 2000 gracefully closes the gates By graceful power is removed from a motor for a time to allow it to stop Depending upon your location this may be 1 second Then reversing relays are switched on Allow for a 50 milli second delay for relays and contactors to disengage and re engage Then main power is applied LED Indicators When an opto input has sufficient voltage applied to it a corresponding LED will illuminate See Figure 6 5 for input LED location These LED s may be turned off on as a group through register 4826 to save some board power PULSE COUNTERS INTRODUCTION Two high speed 3000 pulses second 180 000 pulses minute counters are available at opto buffered inputs IN7 and IN8 While minimum input voltages are the same for the counter as normal opto buffered lines input filter circuitry limits frequency response To obtain a 3 Khz counting capability you should have 12V to ground or open voltage swings at the opto input The pulse source will drive a 2 7K ohm load This
9. If the system still does not respond refer to TROUBLESHOOTING later in this section Testing Press the Enter key on your PC to verify the gt symbol returns The system is now in the immediate mode and is ready for you to start programming Type the following program 10 FOR X 0 TO 2 20 PRINT Hello 30 NEXT 40 PRINT Now type RUN The system will display Hello Hello Hello Ready gt Application Programs Application programs are on the CD under Basic Demos If you downloaded CX 10 basic programs extract them to a directory on your PC Programs are saved in ASCII file format You may edit them using Windows Notepad Wordpad or your word processor UPLOADING AND DOWNLOADING PROGRAMS Downloading programs means transferring them from your PC or terminal to the CX 10 Uploading means transferring them from the CX 10 back to the PC This section explains how to do both of these procedures using generalized instructions for terminal programs When uploading or downloading files select ASCII text format XMODEM YMODEM or other formats are not used Basic does not know when you are typing in a program or if something else laptop or mainframe is sending it characters The upload and download file does not contain any special codes they are simply ASCII characters SETUP AND OPERATION MODBUS and BASIC Uploading programs is simply a process of receiving an ASCII file You or y
10. Modbus Map Volatile Operating System These are integer 16 bit types Function code 3 reads 16 writes Not all registers allow read write or read and write Address range is 4701 to 4800 This group of registers dictate certain operating system functions They are volatile and will generally return a O on power up or reset NOTE These registers are not accessible via modbus port They are accessible only through Basic Unless you will be putting the CX 10 into master mode and running in Basic these registers will not be of interest Read Write Permission Detail O 4701 4779 No read write Returns Reserved Any read or write returns an error error 4780 Contains status of PCON register when CPU resets last Read only COM 3 number of buffer variants See discussion below for this register 4782 Read only COM 3 Read variant from buffer See discussion below for this register Read only COM 3 Master amp slave mode status See discussion below for this register 4 Write only Reset CPU Writing the value 43605 OA A55H to this register causes a CPU reset 4 Write only Clear COM 3 receive buffer and reset master slave status Writing 43605 to this register flushes the receive buffer 4790 4800 Register 4781 operating detail This register returns the number of variants bytes integers floats of data are available to read via register 4785 This registers will contain a value immediately after a successful modbus PRINT 3 is
11. Page 4 3 BASIC SECTION 4 CX 10 no RF modem Modbus Master RS 485 Additional CX 10 or modbus device Additional CX 10 or modbus device Figure 4 3 Expanded IO and modbus devices The configuration in Figure 4 3 allows anywhere from 2 to 31 additional CX 10 or other modbus devices to connect to a modbus master Connections to all modbus devices are through RS 485 The following configurations use the RF modem The first example is shown in Figure 4 4 on the next page A number of CX 10 s may be networked to a modbus master unit SERIAL PORTS Master 4 slaves Modbus Master RS 232 or RS 485 CX 10 with RF modem SECTION 4 Modbus Slaves BASIC RF Link CX 10 with RF modem Additional CX 10 with RF modem Additional CX 10 with RF modem Figure 4 4 CX 10 with RF modem This idea can be expanded to include other modbus devices connected to the CX 10 This is shown in Figure 4 5 below Page 4 4 SERIAL PORTS CX 10 with RF modem Modbus Master RS 485 Additional CX 10 or modbus device Additional CX 10 or modbus device SECTION 4 Optional CX 10 or othe modbus devices Optional CX 10 or othe modbus devices RS 485 CX 10 with RF modem Optional CX 10 or othe modbus devices
12. RS 232 Optional CX 10 or othe modbus devices Figure 4 5 Multiple Slave with RF Modem A large number of slaves can be connected in different manners Note that one slave can be connected via RS 232 to the remote slave on the right side of the drawing If only one CX 10 is connected to the modbus master it may be through RS 232 or RS 485 as shown in Figure 4 Ze These are just some of the ways the CX 10 can be connected in a network Contact Remote Processing to discuss your situation if you have any questions COM3 Baud Rate COM3 baud rate is set by register 4813 Default is 19200 value of 5 Table below shows possible baud rates and the corresponding number to be written to register 4813 _ Register 4813 value RS 485 OPERATING INFORMATION The CX 10 has a so called 2 wire RS 485 port A third wire for ground is necessary Signal lines are designated as 485A and 485B 485A idles high while 485B line Page 4 5 idles low Normally this port is in receive mode However any transmit output via COM3 or the RF modem changes its mode to transmit A master modbus device may be connected to the RS 485 port enabling networking the CX 10 with other CX 10 s or other modbus devices The only requirement is that each modbus device have its own ID which is a modbus requirement anyway RS 485 Termination network RS 485 is designed to operate over long distances gt 1000 meters at high speed Due to cabl
13. Serial pinout top view Additionally unswitched 5V is available at pin 10 on each serial connector Fused battery power 12V is available at P2 pin 5 Switched battery power 12V is available at P2 pin 6 Both battery power 12V and 5V power are switched on and off through register 4823 By default power is turned off Power is turned on by writing a 1 to this register On off condition is stored in EEPROM The on off status will be remembered on power up or reset Page 8 2 SECTION 8 POWER CONSUMPTION Power consumption can be a consideration depending upon how the CX 10 is powered If the CX 10 is powered from a reliable external source such as AC powered DC supply then consumption is not as great of aconcern However if the CX 10 is solar powered then power consumption is more important The CX 10 nominally operates from 12V DC If you are using a reliable AC supply then DC power supply requirements are easily determined Below is a table listing the power consumption for the board each relay and LED and the RF modem CX 10 component Current draw milli amperes CX 10 board only Each relay Each opto LED indicator RF modem receive mode If all relays and LED s are active and the RF modem is ready to receive not transmitting maximum current is 730 milli amperes A line powered DC supply should be rated atl ampere If you have a 12V battery connected then this DC supply sho
14. can be any number from 4 to 16 or possibly higher To figure out what serial ports are available go to the Control Panel on your PC Since Windows operating systems and configurations vary widely the following method hopefully will work in your situation The objective is to get to the Windows Device Manager If you can get there without the following instructions so much the better Select Start for Windows 95 98 ME and XP Windows Vista users click on the Windows logo usually in the lower left corner of the screen If you mouse over this icon a little text box should say Start Find the Control Panel You may need to first select Settings XP users select System Then select the Hardware tab then Device Manager Vista users select Hardware and Sound then Device Manager For all Windows OS select Ports COM and LPT You should set a list of COM ports available on your PC system MODBUS OPERATION You will need a modbus program to read and write to the CX 10 The program PROJECT3 MM is included on the Page 2 2 SECTION 2 CD It is also available at our website www rp3 com downloads If you do not have a modbus program install PROJECT 3 MM on your PC You will also need a VTC 9 serial cable You may optionally connect modbus to the RS 485 port However your PC must have an RS 485 port on it RS 485 ports on a PC are rare Usually you will have to h
15. can store up to 7 digits of data plus an exponent Any extra numbers are not to be relied upon This format has the unfortunate characteristic of returning numbers that are close but not quite the same as the original Some examples Original IEE 754 format 80 30001 80 59999 For all intents and purposes the differences are not significant less than 0 0001245 We used terminology such as faster longer more and less memory These are relative terms For the most part you can use floating point numbers Use integers if you run out of floats keeping in mind the range of values Page 3 1 SECTION 3 it can store 0 65535 STORAGE MEDIA Integer and floating point numbers are stored in SRAM and EEPROM SRAM is temporary volatile memory in the CPU When the CPU cycles power or resets number contents are reset to 0 Registers may be written to SRAM an unlimited number of times EEPROM retain data after power cycling EEPROM data is stored in U2 on the CX 10 board Registers may be written to 1 000 000 times before it wears out Both SRAM and EEPROM may be read an unlimited number of times When should SRAM storage be used When its contents is expected to change frequently Frequently in this case means once minute or so Looked at froma different way writing to EEPROM once minute means the part will wear out in about 1 5 years SRAM is useful for holding data used in modbus communication
16. comments are also ignored Line 2200 with its comment is a part of the program and could be listed The major penalty by writing a program this way is increased download time Notice that you can write a program in lower case characters Basic translates them to upper case Some programmers put NEW as the first line in the file During debugging it is common to insert temporary lines Putting in NEW ensures that these lines are gone Downloading time is increased when the old program is still present If you like to write programs Page 2 7 SECTION 2 in separate modules you can download them separately Modules are assigned blocks of line numbers Start up code might be from 1 to 999 Interrupt handling keypad serial ports might be from lines 1000 to 1499 Display output might be from 1500 to 2500 The programmer must determine the number of lines required for each section Basic automatically formats a line for minimum code space For example you could download the following line of code 10 fora 0to5 When you listed this line it would appear as 10 FOR A 0 TO 5 Spaces are accepted but not stored The following line 10 for a 0 to 5 is compressed and displayed as in the second example above Spaces are removed However spaces as part of a remark or PRINT are not removed Downloading Long Programs The CX 10 has a limited RAM about 6100 bytes You can store much larger programs however up to 32K
17. executed and a good response has been recieved register 4783 5 Reading register 4782 decrements this register by 1 4781 783 787 788 789 NOTE All data must be readfrom the buffer regiser 4784 0 to reset the buffer for another transaction or a valid write to register 4789 to clear the buffer The term Variants means any valid numeric value This can be a bit byte two bytes integer word or four bytes float long Values will be returned via register 4782 in their normalized state Basic automatically interprets these values and returns the normalized value Register 4782 operating detail This register returns variants bytes integers and floats as the result of a master read or write Data is read sequentially in modbus order ID type length ect based on original modbus function code Thus you have access to the entire modbus messge Appendix A Modbus Map Page 7 Appendix A CX 10 Modbus Map Register 4783 operating detail Data returned from this register depends upon the CX 10 master slave status at the moment By default the CX 10 is in slave mode The only way to enter master mode is by the PRINT 3 command When executed in Basic the board enters the master mode Operation of register 4783 is described below based on the OS mode at the moment Register 4783 in slave mode This is the default mode No Basic interaction is necessary when the CX 10 is in slave mode However if your Basic code will
18. on the blue Read Func03 button This initiates a modbus transaction by requesting registers 1 12 from the CX 10 If all goes well you should get numbers under the Data column right center of screen Site Functions 7 Pesar Click Read po o Function 04 to get o Function 05 readings Function 06 L 0 WitefFunciel External voltage Exit Program Battery voltage Figure 2 4 Project 3 Modbus Data and Transaction initiation Note that registers 8 and 9 return external supply voltage to the board and battery charging voltage If external voltage is 0 then power is connected to the battery terminal NOTE Registers 8 and 9 automatically return values in volts only when 12 registers are selected and start register is 1 If you start from a different register or have a different number of registers you will get a number between 0 and 4095 Register 8 returns the supply voltage as a number between 0 and 4095 Register 9 returns the battery backup voltage as a number between 0 and 4095 To convert this reading into volts multiply the value given by 0 007326 Relays are read and controlled via registers 10 and 19 26 To turn on a few relays enter the following parameters in this order Start Reg 10 Page 2 5 SETUP AND OPERATION MODBUS and BASIC of Regs 1 On the right center of the program under Data click in the white area of Reg 10 box Enter a 7 Click on the green
19. you have a question about the RPC 210 and can t find it in this manual call us and ask for technical support Technical support hours are 9 AM to 4 PM mountain time Phone 303 690 1588 FAX 303 690 1875 email info rp3 com website www rp3 com Page 1 2 OVERVIEW SECTION 1 ceo Cera ALLE i g ant 4 Cx 10 Relay 00 ap x1 ey Opto input L ma 3 g Ue g g Y cz la a U os p11 B L re noo y r 07 Cs 5 o Y s COR E Q 00 E pr g B ca 4B Ces i Cres TFs fed u13 ve D i 1 2 ROS ROS R94 RES RBZ RO1 RYO R Y g o CI a anzaz 3228 DODODODO i ae nonoogon 0000 0000 y 25 Se es 0 us ee E c13 ro oo o gt 5 pR o gooo ogo oonga ODIA 01 sl lg 1 e A il 7 lt ig00o00000000000 2 E Coton tI P4 El E B El A El g El IN1 IN2 IN3 IN4 INS ING IN e Gnd Gnd NY a ae A Ya C No Ne F Nc Yu Ak Yi M P1 Figure 1 1 CX 10 Outline External amp battery power Opto inputs 12V and Relays switched 12V Figure 1 2 Page 1 3 SETUP AND OPERATION MOD INTRODUCTION The CX 10 is ready to operate over modbus as soon as you connect it to a PC and apply power This section describes different modbus hardware connection methods The CX 10 is programmable in Basic Generally Basic operation is independent of modbus However interactions can occur For example relays can be turned on or off over modbus A Basic program can perform the same operations It is anticipated that the Basic program will act as a
20. CX 10 USER S MANUAL Copyright 2009 Remote Processing Corporation All rights reserved However any part of this document may be reproduced with Remote Processing cited as the source The contents of this manual and the specifications herein may change without notice TRADEMARKS Intel is a copyright of Intel Corporation Windows Windows XP and Windows Terminal are trademarks of Microsoft Corporation Remote Processing is a registered trademark of Remote Processing Corporation Remote Processing Corporation 7975 E Harvard Ave Denver Co 80231 USA Tel 303 690 1588 Fax 303 690 1875 email info rp3 com internet www rp3 com REV 1 NOTICE TO USER The information contained in this manual is believed to be correct However Remote Processing assumes no responsibility for any of the software or circuits described herein conveys no license under any patent or other right and make no representations that the circuits are free from patent infringement Remote Processing makes no representation or warranty that such applications will be suitable for the use specified without further testing or modification The user must make the final determination as to fitness for a particular use Remote Processing Corporation s general policy does not recommend the use of its products in life support applications where the failure or malfunction of a component may directly threaten life or injury It isa Condition of Sa
21. L C APPLICATION PROGRAMS COMMANDS amp REGISTERS RS 232 PORT PIN OUT Page ii WATCHDOG SECTION 5 RELAY AND OPTO INPUT LINES SECTION 6 ELECTRICAL CHARACTERISTICS 1 Relays eee eet e HO ae 1 Opto Buffered Inputs o oo 1 RELAY OPERATION 2 005 1 Electrical Connection 1 LED Status veian a a dis 2 Modbus Register Interface 3 Opto Buffered Inputs o o oo 4 LED Indicators 04 5 PULSE COUNTERS SECTION 7 APPLICATION PROGRAMS 6 BATTERY CHARGER amp POWER SECTION 8 POWER CONNECTION 04 1 Battery Backup 020s e eee 1 POWER CONSUMPTION 1 APPLICATION PROGRAMS 2 TECHNICAL SPECIFICATIONS SECTION 9 MECHANICAL 00000008 1 CX 10 Modbus Map Appendix A Watchdog Timer 2 0 20 e eee eee eee 4 Non Volatile Intgeger storage 4 Volatile Integer storage oooooooooo o 4 Volatile Operating System 5 Non Volatile Setup ooooocoooooooooo 8 High Speed Counters 0 10 Non Volatile Floating Point Storage 10 OVERVIEW DESCRIPTION The CX 10 is a intelligent IO controller programmable in BASIC and controlled using modbus The BASIC is a variation of the original INTEL BASIC 52 Programming is usually done on a PC with a serial port Additional hardwa
22. RINT formatting statement 2 1 Figure 4 6 Serial port pinout Top view Page 4 7 WATCHDOG INTRODUCTION The CX 10 watchdog timer may be used to reset the CPU should modbus communication or program execution stop Watchdog timers are used primarily in Basic programs Initially a timeout value is set in register 30 Then the program periodically writes a 0 to register 31 Register 31 operates by incrementing once second When its value equals that in register 30 the CPU will reset When the CPU resets all relays are turned off and all volatile integers and floats are erased _ Register Watchdog timeout value 0 disable watchdog 1 255 Timeout seconds Watchdog timer value This register increments every second until it matches the value in Register 30 or until a 0 is written to this register Page 5 1 SECTION 5 RELA Y AND OPTO INPUT LINES INTRODUCTION The CX 10 has 8 relays organized into 3 groups There are also 8 optically buffered inputs Modbus registers 1 and 10 26 are used to access these lines ELECTRICAL CHARACTERISTICS Relays All relays are normally open They are closed when the appropriate register for a relay has a 1 written to it An LED behind the relay lights up when it is energized Relays are rated for resistive load of 3 amperes at 125VAC or 30V DC Minimum load is 10 milli amperes at SV dry circuit If you will be switching inductive circuits such as relays cont
23. Transient absorbers none USER TO ADD Opto Buffered inputs Number 8 Voltage range 0 16 volts DC 5 volts minimum to consider an input ON Maximum frequency 3000Hz for pulse counting Serial Ports Type RS 232 COM 0 and RS 232 or RS 485 COM 3 COM 3 may be used in modbus or ASCII mode ASCII mode sends and receives characters without any protocol Number of ports 2 RF Modem optional Type Digi International XTO9 series Frequency 900 Mhz spread spectrum Power 5V 70 mA idle on 0 65A transmitting 0 5W Page 16 1 TECHNICAL SPECIFICATIONS SECTION 9 CONNECTOR PINOUTS P3 Opto buffered inputs Four primary connectors are along one edge of the board Function A couple of the connectors are multi use while others are dedicated to one function Each connector pinout is Buffered input 1 shown below Buffered input 2 NOTE Pin numbers on board read Left to Right Function Relay group 3 common Buffered input 3 Pl Relays Buffered input 4 Buffered input 5 Buffered input 6 Rel lay 1 elay group 3 relay Buffered input 7 Rel lay 2 elay group 3 relay Buffered input 8 Relay group 3 relay 3 P4 Power and RS 485 communications Function Ground Relay group 3 relay 4 Relay group 2 common Relay group 2 relay 1 Relay group 2 relay 2 Battery 12V connection Ground Function Relay group 1 common External power 12 24V Ground Relay group 1 relay 1 RS 485 A
24. a U4 2 ROS ROS R94 RYJ RSP RBI RYO RES RS 232 E o qe lloro 00000000 Programming or a 0000 0000 gy gt gt D e e E c3 i ooo imm f gc ba po E A ES 22 ll Eea a td pt i El 5 El 2 INI INS INS IN4 INS INS 1N7 IN Gn Gna TAV 12V Gnd MaYe c Yo Ye Ys Yu YK Ye M Pi TD DORA 1 ir ES E DE E 1 U T 307 4a 2 1 6 7 65 4 3 2 1 Ground Battery Ground External power Figure 2 1 Power and serial connection Communication Setup The next step is communicating to your PC There are Page 2 1 SETUP AND OPERATION MODBUS and BASIC two ways to do this Through the programming port or the modbus port Using the programming port means accessing the Basic operating system You will be able to download and run Basic programs through this port You will need a terminal program such as Terraterm Windows Hyper terminal or RPTERM to do this RPTERM is included on the CD or download from www rpc com downloads Using modbus requires modbus network communication software Project 3 MM which is included on the CD may be used for this purpose In both cases you will need an RS 232 serial port If you know your available PC serial port then go to the next section If you don t know or are not sure of an available PC serial port follow the next set of guidelines If you have a serial port built into your PC this is usually COM1 or COM2 If you are using a USB serial adapter this
25. actors or motors then a transient absorber should be placed across the relay contacts at P1 and P2 Transient absorbers vary by voltage AC or DC and power rating Below is a table of possible transient absorbers that may be used These parts are available at Digikey Failure to use transient absorbers could result in shortened relay life Littlefuse 1 5KE220CA 1500W SKP180CA 5000W P6KE33CA 600W Operate time is 10 milli seconds and release time is 5 milliseconds Relays can operate with a battery voltage of 9 volts measured using register 9 Minimum value is 1232 1 1 85 85 8 2 Maximum operations hour is 1800 Maximum cycles under resistive load is greater than 10 000 operations at 30 volts DC Relay life increases when current through contacts is reduced Opto Buffered Inputs Eight opto buffered inputs are available at P3 Input range is 0 16volts The ground for each opto input is common to board ground This kind of opto input affords good protection from transient voltages A minimum of 5 volts is required at an input to turn on the opto isolator and designate that line as ON Input Page 6 1 SECTION 6 resistance is 2 74K ohm Signal source must be able to supply at least 5 milli amps at 12 volts to turn on an input RELAY OPERATION Electrical Connection Relays contacts are connected to P1 and P2 Relays are wired into 3 groups Each relay contact and common are designated by le
26. ation is performed on the next reset 4802 Read or write Clear non volatile integer and floating point registers Default value 165 Writing a value other than 165 to this register will cause the operating system to write 0 s to all non volatile integer and floating point registers Reset is performed on the next reset 4810 Read or write Define COM3 port operation as ASCII or modbus mode 0 ASCII mode 1 modbus mode default 4811 Read or write Modbus ID 0 255 Default 11 Current software will allow a 16 bit slave ID but will only use the lower 8 bits 0 255 4813 Read or write COM3 baud rate 2 2400 3 4800 4 9600 5 19200 default 6 38400 7 57600 4815 Read or write Modbus COM3 timer timout Register value X 10 milli seconds 200 2 seconds default When a print 3 message is sent master mode will wait the amount of time set in this register for data to start being received If the message is not recieved in time the OS writes an error code 254 to register 4783 If data starts coming into the buffer before the timeout expires this register is no longer in effect Another 50 milli second fixed time timeout takes over 4823 Read or write Switched V power control 0 Switched 12V amp 5V off default 1 Switched 12V amp 5V ON Appendix A Modbus Map Page 10 Appendix A CX 10 Modbus Map Register Read Write Permission Permission 4825 Read or write RF modem shutdown 1 enable on Default
27. ave an RS 232 to RS 485 adapter Adapters are available from these sources www bb elec com www jdr com B B Electronics JDR microdevices Generally RS 485 is used over very long distances and between CX 10 boards Its implementation will not be discussed in this section See Section 4 for more info Connect the VTC 9 serial cable to the modbus port as shown above in Figure 2 1 Note that the key notch on the VTC 9 cable faces to the inside of the board Connect the DB 9 end to a PC RS 232 serial port determined from Communication Setup Apply power to the CX 10 if you have not done so already When you first start up Project 3 MM site ID should default to 11 See Figure 2 2 below SETUP AND OPERATION MODBUS and BASIC SECTION 2 J w Control Design Inc Software Toolbox 3 40 3 Multi Master x ai oj x Site Service _ SystemSetup DevreSep AdminSetup Site Information Poll Functions Site Functions Reg it Data Reg7i01 Slave ID 11 Reg7102 __ Fumctionos Reg 7104 H of Regs fro System Time Reg 7105 O Function 06 casscitos E deseoa os ase Get FLOAT Log T Poll Countdown Skip AutoPoll 4 Polling Disabled Reg7107 Function 17 J Reg710g Save as Edit Add New Site Delete Site Reg 7109 E Clear Data System Messages Reg 7110 Set Time zi Exit Program Query Response Raw Data Query Response Text Messages DDE Link Names DDE Link Names
28. be entering the master mode some slave conditions may be of interest Reading regiser 4783 in slave mode can return one of the following values states 4783 return value Idle state no activity Waiting for data Best time to enter master mode Receiving data on COM3 Indicates incoming message Do not enter master mode Invalid packet received CRC Error This is cleared when read or 100 milli seconds after the error is discovered Next state will be a 0 so entering master mode is OK 21 Data receive complete on COM3 Have received message and is processing it Do not enter master mode Register 4783 in master mode This mode is entered by executing a PRINT 3 command in Basic Two modbus function codes are supported 3 and 16 Function code 3 is a query while 16 is a write PRINT 3 syntax depends upon the function code For either function code the following state machine status is returned 4783 return value Idle nothing in 4782 buffer Master is sending via PRINT 3 Master send complete Master waiting for response Invalid packet received CRC error AA IS NOTE If an error occurs 4783 will transistionto one of the error codes below instead of progressing to state 4 or 5 AAA Many states such as and 2 may operate so fast that these values may never be returned Appendix A Modbus Map Page 8 Appendix A CX 10 Modbus Map The format for function code 3 master mode request data is PRINT 3 id 3 a
29. ddress length Where id modbus id of device requesting data from address starting register address length number of registers requesting data The format for function code 16 master mode write data is PRINT 3 id 16 address length datal data2 data3 Where id modbus id of device sending data to address starting register address to write to length number of registers to send datax data to send to slave device This can be integer or floats Data will be sent in proper format integer or float based upn the register address If above 7000 it is float Register addresses 1 6999 will be integer The number of data elements must match the length else a BAD SYNTAX error is returned In practical fact only about 6 or so data elements can be sent at one time Exact number depends upon variable name length You cannot send out all elements in an array or range of registers for example Appendix A Modbus Map Page 9 Appendix A CX 10 Modbus Map Non Volatile Setup These are integer 16 bit types Function code 3 reads 16 writes All allow read and write Address range is 4801 to 4999 This group of registers dictate certain system setup conditions They are non volatile Register_ Read Write Permission Detail 4801 Read or write Reset non volatile setup registers Default value 165 Writing a value other than 165 to this register will cause the operating system to restore defaults to registers 4801 4827 Restor
30. e lengths and high data rates signal ringing will occur A termination network with pull up and pull down resistors is included on the CX 10 The CX 10 presents a 120 ohm impedance to a signal source The other 485 device should have a terminator installed This will present a balance 60 ohm line impedance If more than one device with a terminator is installed the device between the two farthest units should have its terminator removed RS 485 transmitter turn off The RS 485 transmitter is controlled by the operating system or RF modem if sending The 485 transmitter is turned off when the last character is sent SERIAL PORTS RADIO MODEM Using radio modems in a network is similar to using RS 485 in a network The only real difference is the modem connects to the CX 10 through P5 The modem is a Maxstream Digi International XT09 SI This part is available directly from the manufacturer at www maxstream net alternate www digi com or from Digikey www digikey com The modem is licence free 900 Mhz spread spectrum radio Maximum range is 3000 feet in indoor urban environments and up to 20 miles with a high gain antenna and line of site conditions This modem can be configured in a number of different ways Modems shipped from Remote Processing are programmed in the following configuration Serial interface Baud rate 19200 RF baud rate 9600 Transmit power level 500 mW Destination address 7975 Address mask 7975
31. e program in 1 or 2 in this case you need to do an FPROGO in RAM to clear out all programs then download them again gt prog 1 8025H SETUP AND OPERATION To retrieve a program type ROMx where x is the number of the progam In the above example that would be 1 Command Description Erases all Basic programs in flash Use this to start a clean download Creates a programming slot You can have as many programming slots as memory can hold Disables program in slot 1 ROM1 to automatically run on power up or reset Enables program in slot 1 ROM1 to automatically run on power up or reset Switch to ROM slot numbered n If you used PROG above for 3 programs you can go to ROM 1 ROM 2 or ROM 3 and run it When in a ROM slot executing NEW clears out the program in the slot You can then download or enter a new program New will return an error if you attempt to clear a program that is numbered lower than the highest See below Command to use RAM to runa program You must be in RAM to use PROG or FPROGO You can execute a numbered program n in the immediate mode or within a Basic program When you change programs basic variables are erased Variables stored in registers are not affected You can put this command in your downloaded code to immediately execute a program when download is complete MODBUS and BASIC Page 2 9 SECTION 2 WHERE TO GO FROM HERE If you want to d
32. er on the terminal or PC you should see the voltage go positive on the oscilloscope If all of this fails call technical support listed in SECTION 1 Page 2 10 SAVING DATA TO REGISTERS INTRODUCTION There are 2 numerical formats data can be saved as Integer and Floating Point Additionally there are two types of media this data can be saved to EEPROM and SRAM Data is stored to 4 groups of registers described below All registers described in this section are accessible over modbus Number Types The CX 10 works with both types of number formats Each type has features and limitations Integers are in what is known as a 16 bit format and allows numbers between 0 and 65 535 This format is handy for bit manipulation such as opto input or relay status It takes less memory than floating point and is faster to work with Its primary limitation is the limited number range it can store It cannot store negative numbers When using Basic another hidden format integers and floating point numbers are automatically converted into native format In Basic both integers and floats are the same Floating point numbers are stored in a format known as TEEE 754 32 bit This is a standard format used by many computers These numbers take longer to work with and require more memory This 32 bit data length is a single precision format It can store floating point numbers in the range of E As a matter of practical use it
33. es and MTOP are not saved If you only have one program then programming is easy Only NEW RAM FPROGO PROG and PROG2 are of concern Other information concerning program storage structure is not of concern Page 2 8 SECTION 2 If you have multiple programs things get a bit more complicated You can have a large number of different programs all of which can call any of the other programs stored in flash It might help to these of these programs as stacked on top of each other The program at the bottom is referred to as ROM 1 The next would be ROM 2 located above the first program ROM1 can be any length so long as it can fit into flash Same is true with ROM 2 and so on as long as it can fit into flash When editing programs only the highest numbered ROM can be changed For the most part if you have just one program stored to flash you can treat itas RAM That is you can add delete or change a line of code It may take noticeably longer especially when you have a large program before you get the gt prompt If you have several programs editing programs gets a bit more complicated You can have a large number of programs stored in flash EPROM However only the largest numbered program can be edited For example You have programs in slots 1 2 and 3 You can only change edit the program in slot 3 also called ROM 3 Programs in slots 1 and 2 ROM 1 and ROM 2 cannot be edited If you need to change th
34. ever any modbus communication may not work and relays may not turn on Board Operation when its internal power is below 4 5 volts 2 Check the COMO port J1 Make sure the VTC 9F serial cable is oriented correctly The key on the cable corresponds to a silk screen area on the board Remove the connector from COMO Refer to the outline drawing earlier in this section Connect an oscilloscope preferred or a voltmeter to pin 3 Txd and ground Pin 3 should be 6 volts or more negative If you have 6 volts or more cycle power to the board If you have a scope attached you should see a burst of activity With a volt meter you should see a change in voltage Using a Fluke 8060A set to measure AC you should see a momentary reading above 2 volts 3 Check the cable Install the cable and make sure the voltages and output activity are still there Output is from pin 3 on the VTC 9F If not check to make sure something is not shorting the output Wiring is in SECTION 4 SERIAL PORT PIN OUT 4 Check the serial parameters on your PC They should be set to 19200 baud No parity 8 data bits 1 stop Make sure you have set the communications port on your PC to the one the VTC 9F is plugged into 5 Receiving a sign on message and can t enter characters Check U10 pin 8 for at least 6 volts with the serial cable connected to the PC When it is near 0 volts the terminal or PC s Txd line is not connected When you press a charact
35. fer fills program execution is suspended until all PRINT ceo EJcie R38 u12 E out y y gs UU R u gt us u14 Wc ar o ab 2 c11 3 ULE R33 E u13 uz n Ne 2223 I nz 8882882 8000 0000 dl a UUUUUUUU a 3 Ju E AANA a E ERE EE CLELEPEEEeCe r B a Oo0000000000 UAUDUOD IN1 IN2 IN3 IN4 INS ING IN INB eee RS 485 A Modbus 23 485 B Figure 4 1 Serial Port Locations Serial ports are numbered COMO and COM3 COMO is RS 232 only and is used for Basic program development While running a Basic program it can be used for other functions COM3 can be configured to operate as a modbus default mode or ASCII port ASCII port mode is usable only while running a Basic program Additionally COM 3 has 3 ways to communicate to the outside word RS 232 RS 485 2 wire and optional 900 Mhz radio Page 4 1 characters are in the buffer Both ports have a 256 character input buffer When more than 256 characters are received excess ones are ignored SWITCHED POWER Continuous and switched power are available at J2 and J3 This is generally useful when running a Basic program and controlling a external display s backlight or power Register 4823 is used to switch 5V power on and off Battery power is always available See RS 232 Port Pinout later in this section for pinouts SERIAL PORTS COMO SERIAL PORT This port at Jl uses a VTC 9F serial cable to connect external serial devices to
36. inal is 26 volts DC If you are not connecting a battery backup to the CX 10 or you are taking power from another device that is charging a battery and your DC voltage in is under 15 volts then apply power to the Batt terminal on P4 Battery Backup The CX 10 has a temperature compensated lead acid battery charging circuit It can under program or modbus control change between float and charging voltages Virtually any size battery may be connected Maximum charging current is limited however Charge current depends upon temperature around the CX 10 charging solar panel voltage and current demanded by the CX 10 at the time A combination of high charging voltage solar noon high temperatures and CX 10 current draw due to energized relays opto inputs and RF modem transmission could cause the CX 10 to draw power from the battery As a general rule relays will not be energized all the time when used in remote applications Battery sizes of 7 12 AH should be adequate in many instances However if relays are frequently energized especially at night then a larger battery may be necessary Other Power Connections Continuous and switched 5V and battery power are available at several connectors for different purposes Switched 5V is available at both RS 232 serial ports at pin 8 Pin numbering from the top of the PCB is shown below BATTERY CHARGER amp POWER 10 9 w PES 2 1 Figure 8 1
37. irst is as a group through register 10 This is a bit mapped register that controls all relays in one register The second is individually through registers 19 26 inclusive Writing a 1 will turn on a relay while writing a O turns it off A 1 in a register or bit position means a relay is on Registers 10 and 19 26 are read and write types The status of a relay is always reflected in register 10 and its individual register number You could write to register 10 and read its status in register 22 for example On the other hand you can write to register 22 and read its status in register 10 Below is a table of relays wiring designations and register number used to control a relay Relay Connector Common Register number No designatio designator to control or non PCB read relay 1 M 19 2 K M 20 3 H M 21 4 G M 22 5 E F 23 6 D F 24 7 B C 25 8 A C 26 When the specified register set to 1 that relay turns on and makes contact An LED behind the relay also illuminates when a relay is ON All relays may be turned on or off using a single register 10 Register 10 is be useful when a number of relays need to be controlled at the same time This register is bit oriented meaning a sum of weighted values are written to this register to turn relays on or off SECTION 6 Relay No Register 10 weighing value Page 6 3 To turn on specific relays simply add up the value associated with a relay and write it to register 10
38. le that the user of Remote Processing products in life support applications assumes all the risk of such use and indemnifies Remote Processing against all damages FCC NOTICE The CX 10 was not tested for EMI radiation When operated outside a suitable enclosure the board and any cables coming from the board will radiate harmful signals which interfere with consumer and industrial radio frequencies It is your responsibility to properly shield the CX 10 and cables coming from it to prevent such interference P N 2XXX Revision 1 0 OVERVIEW SETUP AND OPERATION SAVING DATA TO REGISTERS SERIAL PORTS TABLE OF CONTENTS SECTION 1 MANUAL ORGANIZATION 000 ocooocooooo MANUAL CONVENTIONS BASIC Statement types Number convention Terminology OPERATING PRECAUTIONS INITIAL SETUP 00d laser sy Serial Port Setup o o ooooooooooo MODBUS OPERATION BASIC OPERATION Application Programs UPLOADING AND DOWNLOADING PROGRAMS Editing programs and programming hints 3 Downloading Long Programs Programming Commands WHERE TO GO FROM HERE TROUBLESHOOTING Programming port problems Number Types STORAGE MEDIA DATA REGISTERS COMMANDS SWITCHED POWER COMO SERIAL PORT Modbus ID s Networking the CX 10 CX 10 interfacing in a system COM3 Baud Rate RS 485 OPERATING INFORMATION RS 485 Termination network RS 485 transmitter turn off RADIO MODEM RF Modem Power ON OFF control ACCESSING SERIAL BUFFERS DISABLING CONTRO
39. les are REGREAD SIN and GET The third types are control statements These include IF THEN ELSE GOTO GOSUB and DIM As such they control or set up the system The final type are multi tasking statements When multi tasking is in effect the operating system monitors for OVERVIEW specified events to happen For the most part multi tasking must be set up in the program Set up consists of a ON multi tasking parameters statement and a subroutine that is executed when conditions are met Example of multi tasking is ONTICK Some statements are both functions and commands depending upon which side of the sign it is on Some examples include ASC and XBY Number convention BASIC convention generally uses decimal numbers between 0 and 9 for data and address information Numbers may be represented in hexadecimal notation Any hexadecimal numbers are represented by OxxH notation A leading 0 is necessary when the first number begins with any letter between A and F Up to six digits may be represented in this manner However many commands and functions only accept 1 2 or 4 hex digits SECTION 1 Terminology A D Shorthand for analog to digital converter An A D measures a voltage and converts it into a number from 0 to 4095 yo are input output devices On the CX 10 this includes relays and opto buffered inputs mSec shorthand for milli second or 1 1000 of a second TECHNICAL SUPPORT If
40. lt Cntl gt lt C gt To disable lt Cntl gt lt C gt so program execution is not terminated execute the following statement DBY 38 DBY 38 OR 1 WARNING Make sure you have a way of stopping program execution in your program There is no way to stop program execution by external means APPLICATION PROGRAMS The following programs are in the Basic Demo directory COM 3 ASCII MODE bas COM 3 PRINT and GET 3 commands Modbus master mode query demo master 3 405 lints bas master 16 405 lints bas Modbus mster mode write demo SERIAL PORTS BASIC SECTION 4 COMMANDS REGISTERS RS 232 PORT PIN OUT The following is a list of Baisic commands and registers Pin outs for J1 and J2 are shown below Unused pins are used for serial I O Register are explained in Appendix open A Basic commands and functions are explained in the 4 Basic Programming section in this manual Jt J2 Name Direction s gt l COM 0 COM1 from card __ Commana Battery supply Set COM3 operating mode o an po e Set modbus ID COM 3 baud rate Modbus timeout timer Switch 5V and battery power control Switched 5V is controlled by register 4823 Returns a character from the serial buffer Outputs program listing 1 0 Et 9 Outputs data in various formats Prints to a specified port or if COM 3 in modbus mode send out S a modbus message v 4 Print out n number of spaces E ee Tabs to predetermined positions aa P
41. o mo Mo Ho C DNP 3 0 START gt gt gt Store and Forward Path gt gt gt gt gt END 3 Flow Automation Modbus _ReadSrF _Wiite SnF C Extended Modbus SnF Text Messages SnF Raw Messages Directory to Save Float Data Lo Select C devI Project3V3MM 40b Directory About Software Figure 2 3 Communications Setup Page 2 4 SETUP AND OPERATION MODBUS and BASIC Now click on the Site Service tab at the top left of the program If not already done set Start Reg to and of Regs to 12 as shown below This will return the status of digital IO and power applied to the board w Control Design Inc Site Service Site Information Poll Functions Set start register to 1 System Time 13 05 31 Set number of registers to 12 Get ASCII Log M Get FLOAT Log M Poll Countdown Skip Auto Poll MV Polling Disabled Save as Edit Add New Site Delete Site System Messages Query Less CRC 11300012 Hex Length 0 Hex Value zl Query Response Raw Data Slave 11 Query 1130001269101 Start Timer 47108 End Timer 47110 Timer Count 47108 Exit Timer for Asd gt 11324000000000000 009327 160000000196 228 Number of bytes in Com Port 30 Red correct ID gt 11 Received CRC 196 228 Calculated CRC 196 228 Query Response Text Messages Slave 11 Function 03 Response OK DDE Link Names DDE Link Names y Software Toolbox 3 40 3 Multi Master SECTION 2 Click
42. o this Turn to Section Know more about serial ports Modbus connections including RF RS 485 and RS 232 Use memory to save variables and data Relay wiring and ON OFF control Use opto buffered inputs Use high speed counter Refer to the table of contents for a more detailed listing Measure charge and battery voltages TROUBLESHOOTING You would probably came to this section because you could not get either the Basic sign on message or talk Modbus to your PC Refer to the appropriate section below to begin Programming port problems The following are troubleshooting hints when you can t get anything 1 Check the power source There are two board power inputs Battery and external solar power Generally you should apply power to the external input This voltage should be above 7 volts If you are so inclined measure voltage at U6 and C12 terminal marked 5V Voltage there should be 5 0 25 volts Make sure the 5 volt supply is clean If it dips intermittently to 3 volts due to switching noise or ripple the card will reset If the noise is frequent enough the card will be in permanent reset Some switching power supplies require a minimum load to operate Check your power supply specifications The CX 10 draws about 90 milli amperes when no relays are energized or opto inputs are on SETUP AND OPERATION MODBUS and BASIC SECTION 2 The CX 10 CPU will function down to around 3 volts How
43. our program simply need to send LIST to receive the entire program Downloading a program requires transmitting an ASCII file As you type in or download a line Basic tokenizes that line The time to do this depends upon its complexity and how many lines of code have been entered Basic must finish compiling a line before starting the next one When a line is compiled a gt character is sent This should be your terminal programs pacing character when downloading a program If your communications program such as HyperTerminal cannot look for a pacing prompt set it to delay transmission after each line is sent A 100 ms delay is usually adequate but your program may be long and complex and require more time A result of a short transmission time is missing or incomplete program lines Editing programs and programming hints Files uploaded or downloaded are simply ASCII DOS text files No special characters or control codes are used You may create and edit programs using your favorite word processor or editor Just be sure to save files in DOS text format A technique used to further program documentation and reduce code space is the use of comments in a downloaded file For example you could have the following in a file written on your editor REM Read charge voltage REM and convert to volts 2200 a regread 8 007326 The first 2 comments downloaded to the RPC 210 are ignored Similarly the empty lines between
44. port Operating mode is changed in register 4810 Writing a 1 sets this port to operate in modbus while a 0 sets it to operate in ASCII ASCII mode is useful if the CX 10 is not running modbus and a serial keypad amp display are attached If you will not be running a Basic program default operation should be left as modbus While operating in modbus protocol mode function arguments 3 and 16 are recognized Current operating BASIC Page 4 2 SECTION 4 system supports 8 bit address 0 255 Future operating systems may support 16 bit address Default modbus address is 11 This is changed through register 4811 ASCII mode operates in a similar manner as COM 0 when a Basic program is running Use PRINT 3 and GET 3 to send and receive data The CX 10 can operate in modbus master mode See registers 4781 4783 for more information Modbus ID s A modbus master device may be connected to a larger network through 450 Mhz radios The master in this case will have its own modbus ID However slaves connected to this master can have the same ID s as other modbus masters It is a good idea to make each CX 10 device a unique when using the RF modem The RF modem can under ideal conditions send and receive up to 40 miles If there will be other similar RF modems it is best to make each CX 10 and other modbus units have their own ID in case another master can be received the slave Networking the CX 10 The CX 10 may be pa
45. re features include e Flash EPROM allows program updates in the field without removing any parts e Eight 125VAC relays e Eight optically buffered inputs e Modbus communication through RF RS485 or RS 232 e Temperature compensated 12V battery charger e Non volatile EEPROM stores configuration e Battery and charge voltage monitor e Two pulse counters Description Part Number IO board with 8 relays 8 opto buffered inputs 12V battery charger One RS 232 programming display port One RF RS 232 or RS 485 port programmable for ASCII or modbus As above with 900 Mhz spread spectrum modem MANUAL ORGANIZATION Most users initially relate to a device based on what it does physically Initial concerns are how do I turn on off relays and how do I get an input This manual is organized by input output functions The CX 10 can be thought of as having two independent operating modes Modbus and Basic The board will operate in either mode and both modes can operate simultaneously For example modbus can be used to control relays and monitor opto status A Basic program can do the same Neither mode is dependent upon the other However interactions can occur For example a Modbus command may turn a relay on while a Basic command may turn it off The status of a relay depends upon which mode got to it last Basic can act as a watchdog actinag as a failsafe if modbus communications should stop Basic can al
46. rge Ideal eC voltage voltage charge 14 71 15 74 15 6 13 87 14 83 14 88 gar ia The temperature sensor is R24 located next to the Batt V adj pot Under ideal conditions this resistor would be at the same temperature as the battery When the CX 10 is mounted in a box outside it is probable that the temperature in the box will differ from the battery For this reason the battery ideally should be located near R24 Depending upon battery size and use battery voltage control may or may not be necessary If relays will be on when external power is missing solar control then more active battery management is necessary If the battery is drained excessively the hgher charge voltage should be applied for an hour or two each day to prevent sulfation This can be done under modbus or Basic program control Register 8 returns the supply voltage as a number between 0 and 4095 Register 9 returns the battery backup voltage as a number between 0 and 4095 To convert this reading into volts multiply by 0 007326 In Basic this is done as follows Page 8 1 SECTION 8 100 A REGREAD 8 0 007326 Project 3 will also return supply charging or battery voltage when registers 1 12 are returned POWER CONNECTIONS DC power to the CX 10 is usually to P4 to the terminal marked Ext Pwr Use this terminal for solar panel power and AC line power DC supplies with voltages above 12 volts Maximum voltage at this term
47. rt of a modbus network with other CX 10 s or modbus devices under the right conditions There are two conditions where this is possible 1 Master modbus communications take place over RS 485 2 Master modbus communication take place using the RF modem Under this condition the RS 485 port may be used to connect to other modbus devices RS 232 may be used to communicate to a modbus master However due the nature of RS 232 only one device may be connected CX 10 interfacing in a system The CX 10 is connected to a system in one of several ways Two broad considerations are Is the CX 10 going to be wired to a master or use an RF modem Will there be other modbus slaves in the system The drawings below illustrate some of these possible configurations Be sure to read the section RS 485 OPERATING INFORMATION below RS 485 can operate as a 2 or 4 wire system The CX 10 is a 2 wire system Make SERIAL PORTS sure your master can operate as a 2 wire RS 485 if you choose that method Figure 2 below shows the simplest configuration The CX 10 simply connects to a master via RS 232 or RS 485 serial port No RF modem is necessary Modbus Master do or CX 10 no RF modem Figure 4 2 Basic Connection Use this configuration when you want to expand IO You can connect to the CX 10 using RS 232 or RS 485 The next configuration allows for more CX 10 or modbus devices on a RS 485 network
48. s EEPROM is useful for storing constants such as time delays offsets and multipliers DATA REGISTERS There are 4 groups of data or numeric storage registers shown in the table below Numeric ranges are inclusive meaning you can use all the numbers shown 4001 4256 EEPROM 7033 7096 SRAM Floating point 7101 7356 EEPROM Floating point You have 256 integer and floating point numbers that can be stored in EEPROM You have 128 integers and 64 floating point numbers in volatile SRAM SAVING DATA TO REGISTERS SECTION 3 COMMANDS The following is a list of Basic commands used to read integer and floating point data REGREAD Read data from a register REGWRITE Write data to a register Page 3 2 SERIAL PORTS DESCRIPTION The CX 10 has two serial ports that interface to a variety of devices In addition the port designated as COM3 can change personality This section describes their characteristics and how to use them Battery and switched 5V power are also available at J1 and J2 er RS 232 Modbus sngnow ENOJI RS 232 Programming BASIC SECTION 4 Under the right conditions the CX 10 can be networked with other CX 10 or modbus devices The following paragraph may be important to Basic programmers Each port has a 256 character interrupt driven circular input and output buffer This allows characters to be sent out using PRINT without slowing down program execution However if the PRINT buf
49. safety program should communications fail over modbus OPERATING PRECAUTIONS The CX 10 is designed to operate in industrial settings However it is not indestructible To avoid damaging the CX 10 observe the following precautions 1 Limit power supply voltage to 30 volts DC The board will not operate with AC voltage as a power source 2 Limit relay connections to 115VAC 2 amperes 3 Limit opto buffer inputs to 24 volts BUS and BASIC SECTION 2 INITIAL SETUP You will need the following equipment to verify operation for either modbus operation or Basic programming eCX 10 embedded controller e VTC 9F serial cable Power supply 9 to 30 VDC E 500 ma Refer to SECTION 4 SERIAL PORT PIN OUT for wiring information to make your own serial cable Connect your external power to the terminals marked Ext Pwr and Gnd on the board External power supply goes to Ext Pwr termial See Figure 2 1 for location You may connect a 12V lead acid battery to the terminals marked Batt and Gnd Battery terminal goes to Batt terminal The next steps will take you through communicating to the CX 10 through modbus or a terminal program Either method can be used to verify initial communication ceo OD c18 RoR ute 3 E ca 3 Cx 10 Relay q AD eee cof eae oR O ue z h aed a ult A RS 232 E De ABE o oo E z O H j s O LB Modbus i 22 soe OO BR hag 5 Ela O g RE E un
50. side Relay group 1 relay 2 RS 485 B side Ground Ground Fused battery 12V power MECHANICAL Switched battery 12V power Size 7 750 x 3 450 Ground Mounting Four mounting hole centers are 0 250 from each corner One in the middle is shown in Ground the drawing below Standoff hole sizes are for 4 40 screws Standoffs are 0 281 in diameter Standoffs place the PCB 0 7 above the PCB Page 16 2 TECHNICAL SPECIFICATIONS 7 75 SECTION 9 3 45 0 750 Sa e 4 050 E Holes in corners are 0 25 from each edge Figure 9 2 Mounting hole locations Page 16 3 Appendix A CX 10 Modbus Map The following is the Modbus Register map for the CX 10 EAr ETE Description Start Start Register End End Register Type Non volatile Integers Operating System Registers Setup Registers 4801 4827 High speed counters 7001 7002 Volatile floating point numbers 7033 7096 Non volatile floating point 7101 7356 Float numbers Appendix A Modbus Map Page 4 Appendix A CX 10 Modbus Map Hardware I O Registers These are all integer 16 bit types Function code 3 reads 16 writes Register_ Read write permission Detail 2222 Read only Opto buffered digital inputs returned as bits 0 7 Read only Charge solar panel input Multiply this number by 0 007326 to obtain volts Range is 0 30 volts Read only Battery voltage Multiply this number by 0 007326 to obtain volts
51. so organize IO status and voltages in a way Page 1 1 SECTION 1 that is more suitable to a Modbus IO program For example if a specified input were to go low this could signal a critical condition The basic could set a flag in a register so that a Modbus IO program could easily recognize a fault condition This manual presents modbus and basic as two separate operating modes within each hardware description MANUAL CONVENTIONS Information appearing on your screen is shown in a different type Example MCS 51 tm BASIC V2 0 Version CX 10 Portions Copyright c 2008 Control Design and c 2009 Remote Processing Corp Build Feb 02 2009 16 41 10 NOTE Text under this heading is helpful information It is intended to act as a reminder of some operation or interaction with another device that may not be obvious WARNING Information under this heading warns you of situations which might cause catastrophic or irreversible damage Wxla b Denotes jumper block pins a b are the pins to connect lt xxx gt Paired angle brackets are used to indicate a specific function key on your PC keyboard For example lt esc gt means the escape key Jx N Designates a pin number on a connector BASIC Statement types There are 4 generic types of BASIC statements The first type is a command A command does something generally an output Examples of commands are PRINT CLEAR and REGWRITE A function returns a value Examp
52. the port The cable consists of a 10 pin IDC connector wired one to one to a DB 9 connector Line 10 is simply cut off The pin out is designed so it plugs directly into the 9 pin serial port connector on a PC Baud rate is fixed at 19 200 8 data no parity 1 stop bit COMO is used for programming During run time it may be used as a general purpose serial port When used for programming or with the INPUT statement it accepts ASCII character values from 0 to 127 When used with the GET function it will return ASCII values from 0 to 255 COMO does not have handshaking lines COM3 SERIAL PORT COM3 is an RS 232 radio modem and or RS 485 port A VTC 9F serial cable described above is used for RS 232 level communications RS 232 is from header J2 RS 485 is from P4 and is designated as 485A and 485B Additionally a 900 Mhz radio modem may be plugged into the board All three ports may be used more or less at the same time This is both convenient and a danger The convenience is the radio modem may be used to talk to both the CX 10 and other devices over RS 232 or RS 485 The danger is when two devices talk at the same time Data will collide become garbled and unusable It is important therefore that any devices connected to the CX 10 be slaves and not initiate any transmission unless requested Protocol Modes COM 3 can operate as a modbus protocol port or ASCII port By default COM 3 operates as a modbus
53. tters A M Letters T and J are not used 2 groups have 1 common power and 2 switched relays 1 group has 1 common and 4 switched relays First group schematic is shown below P2 Relay 8 Relay 7 Figure 6 1 Relay group 1designations Terminal designated as C is common line for relays 7 and 8 Second group schematic at P1 is wired similar to the first group P1 is Relay 6 Relay 5 Figure 6 2 Relay group 2 designations Terminal designated as F is common line for relays 5 and 6 RELA Y AND OPTO INPUT LINES The third group has 4 relays and one common as shown below P1 dee ie de Relay 4 Relay 3 Common Relay 2 Relay 1 Figure 6 3 Relays group 3 designations snqnpow ENOI ar Us i eas 3 Uo Ga Opto Inputs Grounds SECTION 6 Terminal designated as M is common for relays 1 4 Note that designators T and J are not used Relay group locations are shown in Figure 6 4 below LED Status The status of a relay is visually determined by the LED immediately behind it When illuminated that relay is energized CX 10 Relay I Opto input D3 5 ar TE io Oe E i 2 R96 R95 R94 R93 R92 R91 RYO RBI DOd00000 Group 1 Group 2 Group 3 Relay Groups Figure 6 4 Opto Buffered inputs and Relay Groups Page 6 2 RELA Y AND OPTO INPUT LINES Modbus Register Interface There are two ways relays can be controlled and status read F
54. uld be between 15 24 volts DC If battery backup is not required 12V DC may be used BATTERY CHARGER amp POWER SECTION 8 Solar power requirements are more complex to APPLICATION PROGRAMS determine Power requirements depend upon estimated time relays will be on how many will be on how many opto buffered input status LED s will be on if any and how often the RF modem will be on and transmitting The following program is in the Basic Demos directory Program battery charger bas is a stub program It is a part of the main program However with little modification is can be a stand alone program Some power can be saved by turning the input LED indicators off via register 4826 __ File Name RF modem power during transmit can be significant battery charger bas Allow for 1 3 amperes at 12V A packet transmit takes about 2 seconds so current draw will be this much for that period of time czo cis di f Di a g CX 10 Relay 0 we Opto Input 38 O g al ho O wee Oen AAG ui e EDS oR cot s sue a TO Crs R us mm m MA A 1 2 RSs RSS R94 RES RIZ ASI RIQ v 6 ca zaz H y Reo D7 5 a cas azza i 00000000 ae 00000000 OOD 0000 a pS Sher Shes Shes e o hee a c13 a 24 Ji Tu ano oo LIM Aa af a zs ale a sil lg Io E AER 8 aioi T o VU ODODDUDD m3 E BEH 3 E 2 m 000000 cod ono PV tev eno Ya Na fe Yo Ye le Yo YH YK Ye mm 8 7 6 S 3 2 1 8 7 6 S 4 3 2 1 as po
55. wer Switched 12V power R24 Temperature sensor External power Figure 8 1 Power IO Page 8 3 TECHNICAL SPECIFICATIONS CPU Atmel AT80C51RE2 Power Supply Inputs 12V minimum at battery 0 25V at External power with 12V battery Current draw 70 ma nominal no RS 232 devices attached No relays on Each relay draws 45 milli amps when energized No opto inputs on When LED is illuminated board current draw is increased 10 milli amperes LED No RF modem installed or is powered off Current draw all relays on 0 5 amps maximum Battery charger Temperature compensated for 12V lead acid Voltage monitoring Battery level may be checked through register 9 A number between 0 and 4095 is returned Multiply this number by 0 007326 to obtain voltage Charge level is read through register 8 A number between 0 and 4095 is returned Multiply this number by 0 007326 to obtain voltage Maximum charging current 1A depends upon ambient current Memory 2K byte EEPROM Atmel AT25160 Larger serial EEPROMs may be installed but extra capacity is not recognized or used OS automatically initializes EEPROM at first use Maximum writes 1 000 000 Maximum reads unlimited Storage life 10 years SECTION 9 Relays Number 8 Configuration normally open Relays are connected in groups Each group has its own common power line Rating resistive load 125VAC 3A 32VDC 3A Minimum load 10 milli amps
56. y Figure 2 2 Initial Project 3 Screen Page 2 3 SETUP AND OPERATION MODBUS and BASIC SECTION 2 Next step is to set the communication port to match your Select the Com port that is connected to the RS 232 PC See Communication Setup above to help modbus port determine what ports you have available if you do not know Make sure the Baud Rate is set to 19200 Click on the System Setup tab at the top of the All other parameters under Serial Port Setup should program screen You should get a screen similar to not have to be changed below i Control Design Inc 40 3 Multi Master loj x Adnin Sep Software Toolbox 3 Poll Retry Setup This site set ASCII Log Serial Port Setup Com port Master Set Poll Interval 2 Minutes a s z Comm Port ja y select TR Packet Size Poll Delay lo Minutes Ps a C 32 Bytes Baud Rate 18200 y aster o 64 Bytes Feia In gt Baud rate to Retries 0 C Master E C 128 Bytes 19200 H Data Bits 8 v Retry Delay 2 Secs C Master D C Master E Save Settings Stop Bits fi z Store and Forward SnF Setup Modem SnF Setup for Modbus system Enter ID of unit data will start from in SnF Origin Then enter ID s of forwarding unit s in SnF 1 thru 4 box Complete path by entering RTU ID that will receive data in Destination ID box E SnF Protocol Select SnF Origin SnF1 SnF2 SnF3 SnF 4 Destination ID Bristol BSAP 2
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