ABB XIO-00 User manual

ABB MEASUREMENT & ANALYTICS | USER MANUAL
Extendable IO (XIO)
XIO-00, XIO-04, XIO-08
Smart, extendable IO
Measurement made easy

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Contents
Contents ................................................................................................................................ 2
List of tables .......................................................................................................................... 7
Additional information............................................................................................................ 8
Cyber security........................................................................................................................ 8
Malware Prevention............................................................................................................... 8
Safety .................................................................................................................................... 9
Potential safety hazards ......................................................................................................... 9
Compliance .......................................................................................................................... 10
Waste Electrical and Electronic Equipment (WEEE).................................................................... 10
FCC RF Compliance ............................................................................................................. 10
1Product overview............................................................................................................. 11
2Physical Description......................................................................................................... 13
2.1 XIO Housing .............................................................................................................. 13
2.1.1 Enclosures.................................................................................................... 15
2.2 Electronic board ......................................................................................................... 16
2.2.1 Communication ports ..................................................................................... 16
2.2.2 TFIO expansion interfaces ............................................................................... 20
2.2.3 External power supply requirements ................................................................. 21
2.2.4 Power port.................................................................................................... 21
2.2.5 Security switch.............................................................................................. 22
2.2.6 Reset button................................................................................................. 23
2.2.7 COLD button................................................................................................. 23
2.2.8 Super capacitor ............................................................................................. 23
2.3 Embedded software and data ....................................................................................... 23
2.3.1 Operating system .......................................................................................... 24
2.3.2 Applications .................................................................................................. 24
2.3.3 Configuration files.......................................................................................... 25
2.3.4 Customer data collection files .......................................................................... 26
2.4 User interface ............................................................................................................ 26
2.5 Secure service access interface..................................................................................... 26
3Installation...................................................................................................................... 26
3.1 Site planning and requirements .................................................................................... 26
3.1.1 Enclosure requirements .................................................................................. 26
3.1.2 Location requirements .................................................................................... 27
3.1.3 Mounting requirements................................................................................... 27
3.1.4 Install antenna (for wireless functionality).......................................................... 27
3.2 Wiring requirements ................................................................................................... 27

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3.3 Unpack and inspect..................................................................................................... 27
3.4 Basic hardware installation........................................................................................... 28
3.4.1 Ground the controller ..................................................................................... 28
3.4.2 Standalone mounting ..................................................................................... 28
3.4.3 Mounting when using an enclosure ................................................................... 29
3.4.4 Wire serial communication ports....................................................................... 29
3.4.5 Connect TFIO modules.................................................................................... 32
3.5 Power the XIO ........................................................................................................... 33
3.5.1 Power-on sequence........................................................................................ 34
3.5.2 Power with external power source .................................................................... 34
4Startup ............................................................................................................................ 35
4.1 Download PCCU32 from the ABB global website............................................................... 35
4.2 Install PCCU32........................................................................................................... 37
4.3 Establish local communication ...................................................................................... 38
4.3.1 Using the USB port ........................................................................................ 38
4.3.2 Using the Ethernet ports ................................................................................. 40
4.4 Change PCCU to Expert view (required) ......................................................................... 43
4.5 Configure basic XIO parameters.................................................................................... 44
4.6 Configure network communication (4-port switch mode) ................................................... 46
4.6.1 Sample connections ....................................................................................... 46
4.6.2Configuration overview ................................................................................... 47
4.6.3 Configure the XIO.......................................................................................... 48
4.6.4 Configure the RMC......................................................................................... 51
4.7 Configure serial communication applications (COM ports on XIO-04 and XIO-08)................... 58
4.7.1 Configure COM port for communication with ABB devices...................................... 59
4.7.2 Configure XIO application export ...................................................................... 71
4.7.3 Verify XIO application export on the RMC........................................................... 72
4.7.4 Configure measurement applications to use XIO values ........................................ 75
4.8 Configure Ethernet-Serial Passthrough ........................................................................... 76
4.8.1 Configure the XIO.......................................................................................... 77
4.8.2 Configure the RMC......................................................................................... 84
4.8.3 Configure the peripheral ................................................................................. 89
4.8.4 Configure measurement applications to use XIO values ........................................ 90
4.9 Configure the I/O Interface for TFIO module support........................................................ 91
4.9.1 Connect the TFIO modules to the XIO ............................................................... 92
4.9.2 Add and export the I/O Interface application ...................................................... 93
4.9.3 Verify TFIO module detection on XIO ................................................................ 95
4.9.4 Clear the Fail Safe Watchdog alarm (remote TFIO control).................................... 98
4.9.5 Clear the Fail Safe Watchdog alarm (local TFIO control) ......................................100
4.9.6 Verify I/O interface application export on RMC ...................................................102
5Calibration ..................................................................................................................... 103

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6Basic troubleshooting .................................................................................................... 104
6.1 RMC unable to detect or communicate with the XIO ........................................................104
6.1.1 Verify RMC-XIO connection (physical connection) ...............................................106
6.1.2 Verify the IP parameter configuration (IP communication) ...................................107
6.2 XIO applications not displaying on the RMC....................................................................110
6.3 RMC failure to receive data from XIO passthrough ..........................................................112
6.3.1 Missing or mismatched TCP port......................................................................113
6.3.2 Missing or incorrect XIO serial port ..................................................................114
6.3.3 Incorrect protocol selection ............................................................................116
6.3.4 Mismatched serial communication parameters ...................................................116
6.4 Fail Safe Watchdog alarm does not clear .......................................................................118
6.5 Network Diagnostic Tools............................................................................................121
7Configure security (recommended) ................................................................................ 121
7.1 Access points............................................................................................................121
7.2 Communication interfaces...........................................................................................121
7.2.1 User-enabled services ...................................................................................122
7.2.2 Open Transmission Control Protocol (TCP) ports.................................................122
7.3 Denial of service (DOS) threshold rates.........................................................................124
7.4 Security guidelines ....................................................................................................124
7.5 Configure bi-level security with security switch ...............................................................125
7.5.1 Configure non-default XIO security code on the RMC ..........................................127
7.6 Configure Role-Based Access Control (RBAC) .................................................................128
7.6.1 Default access roles ......................................................................................128
7.6.2 Set up and create a new RBAC security control file .............................................129
7.6.3 Edit the security file ......................................................................................130
7.6.4 Create a new user account .............................................................................130
7.6.5 Enable RBAC authentication on communication ports ..........................................134
7.7 Secure the SSH/SFTP service ......................................................................................137
7.7.1 Supported SSH/SFTP accounts ........................................................................137
7.7.2 SSH/SFTP authentication ...............................................................................138
7.7.3 Update default SSH/SFTP keys........................................................................138
7.7.4 Enable SSH/SFTP..........................................................................................152
8Service and maintenance ............................................................................................... 152
8.1Preserve data and configuration...................................................................................153
8.1.1 Collect data .................................................................................................153
8.1.2 Save the device configuration .........................................................................156
8.2 Restore the device configuration ..................................................................................161
8.3 Use the configuration from another XIO ........................................................................163
8.4 Update device software ..............................................................................................165
8.4.1 Security requirements before upgrade..............................................................165
8.4.2 When to upgrade ..........................................................................................165

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8.4.3 Software packages........................................................................................166
8.4.4 Determine device software part number/version ................................................166
8.4.5 Update software ...........................................................................................168
8.5 System restart..........................................................................................................169
8.5.1 Restart type overview....................................................................................169
8.5.2 Warm restart with the RESET button................................................................171
8.5.3 Warm restart from the device loader................................................................171
8.5.4 Warm restart from PCCU Entry mode ...............................................................172
8.5.5 Warm restart from terminal mode ...................................................................172
8.5.6 Cold restart from the device loader..................................................................173
8.5.7 Cold restart from terminal mode .....................................................................174
8.5.8 Factory restart from the device loader..............................................................175
8.6 Remove and restore power .........................................................................................176
8.6.1 Remove power from the device .......................................................................176
8.6.2 Reconnect power to the device........................................................................177
8.6.3 Remove the XIO from the DIN rail ...................................................................177
8.6.4 Return device for repair .................................................................................178
8.7 Maintain cleanliness of the XIO ....................................................................................178
9Ethernet connectivity scenarios...................................................................................... 178
9.1 Connection types supported by the XIO.........................................................................179
9.1.1 Connection types ..........................................................................................179
9.1.2 Ethernet modes............................................................................................180
9.2 IP parameter configuration..........................................................................................180
9.2.1 IP Addressing per Ethernet mode ....................................................................181
9.2.2 Dynamic and static addressing........................................................................181
9.2.3 Private and public addressing..........................................................................182
9.3 First-time local communication (4-port switch mode).......................................................183
9.3.1 Configuration ...............................................................................................183
9.4 Network communication on 4-port switch mode..............................................................184
9.4.1 Daisy-chain connection support by the RMC ......................................................184
9.4.2 Local access by host......................................................................................186
9.4.3 Remote access by host ..................................................................................187
9.4.4 Device-to-device communication .....................................................................190
9.5 Enterprise and industrial (3-network) support ................................................................191
9.5.1 Configuration ...............................................................................................192
9.6 Enterprise and industrial (4 Network) support ................................................................193
9.6.1 Configuration ...............................................................................................193
9.7 Port forwarding .........................................................................................................194
9.7.1 Configuration overview ..................................................................................195
9.7.2 Ethernet interface IP addressing guidelines .......................................................196
9.7.3 Determine field connections............................................................................196

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9.7.4 Use A-Network ports for field LAN connections...................................................196
9.7.5 Use A-Network ports for WAN (uplink) connection ..............................................198
9.7.6 Enable port forwarding ..................................................................................199
9.7.7 Define port forwarding rules ...........................................................................199
9.7.8 Verify access to field devices with PCCU............................................................200
10 Wi-Fi®connectivity scenarios ......................................................................................... 202
10.1 Connections supported by Wi-Fi modes .........................................................................203
10.2 IP parameter configuration..........................................................................................203
10.3 Wireless network communication .................................................................................204
10.3.1 Local point-to-point wireless access to XIO (Wi-Fi AP) by host ..............................204
10.3.2 Local wireless access to RMC by host ...............................................................205
10.3.3 Local wireless access to XIO (Wi-Fi client) by host..............................................206
11 Product warranty........................................................................................................... 206

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List of tables
Ta b le 0 -1: Related documents ..................................................................................................... 8
Ta b le 1 -1: XIO models ............................................................................................................. 13
Ta b le 2 -1: XCORE enclosures available ....................................................................................... 15
Ta b le 2 -2: Ethernet ports ......................................................................................................... 19
Ta b le 2 -3: Power source requirements ........................................................................................ 21
Ta b le 2 -4: Power connector specifications.................................................................................... 21
Ta b le 2 -5: Applications available on the XIO ................................................................................ 24
Ta b le 3 -1: Serial communications specifications ........................................................................... 29
Ta b le 3 -2: Ferrule specifications................................................................................................. 30
Ta b le 3 -3: TFIO modules .......................................................................................................... 32
Ta b le 4 -1: USB cabling............................................................................................................. 38
Ta b le 4 -2: Ethernet cabling....................................................................................................... 41
Ta b le 4 -3: Required station setup .............................................................................................. 45
Ta b le 5 -1: Calibration per application scenario ............................................................................103
Ta b le 7 -1: Default communication ports on the XIO .....................................................................121
Ta b le 7 -2: Wireless interfaces in XIO .........................................................................................122
Ta b le 7 -3: User-enabled services on the XIO...............................................................................122
Ta b le 7 -4: Open TCP ports on the XIO .......................................................................................122
Ta b le 7 -5: Denial of Service (DOS) threshold rates ......................................................................124
Ta b le 7 -6: XIO security guidelines.............................................................................................124
Ta b le 7 -7: Per-port RBAC authentication options..........................................................................134
Ta b le 7 -8: Security keys..........................................................................................................138
Ta b le 8 -1: Restart types..........................................................................................................170
Ta b le 9 -1: XIO IP addressing per Ethernet mode .........................................................................181
Ta b le 9 -2: Reserved private address blocks ................................................................................182
Ta b le 9 -3: Configuration for first-time local communication ...........................................................184
Ta b le 9 -4: Configuration for remote communication with networked XIO (ports A1 or A2) ..................190
Ta b le 9 -5: Required connections for XIO – RMC communication .....................................................191
Ta b le 9 -6: Enterprise and industrial networks - configuration.........................................................191
Ta b le 9 -7: Separate 4-network support......................................................................................193
Ta b le 9 -8: Supported mode by Ethernet ports.............................................................................196
Ta b le 9 -9: Reserved TCP ports on Totalflow devices......................................................................200
Ta b le 1 0 -1: Connections supported by Wi-Fi modes .....................................................................203
Ta b le 1 0 -2: IP parameter configuration......................................................................................203

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Additional information
Additional free publications are available for download at www.abb.com/upstream or by scanning this
code:
XIO Product page
Table 0-1: Related documents
Document
Document number
XIO Data sheet
DS_2102774-EN
XIO Quick Start Guide (tri-fold leaflet)
2106425
XIO Interface Application Guide
2107011
Ethernet-Serial Passthrough Application Guide
2107010
Network Communication Application Guide
2107013
I/O Interface Application Guide
2107012
RMC User Manual
2105552
TFIO Module User Manual
2101226
Wi-Fi Antenna Kit
2106123
Cyber security
This product is designed to be connected, and communicate information and data, via a network interface.
All Totalflow products should be connected to a secure network. It is the customer's sole responsibility to
provide and continuously ensure a secure connection between the product and the customer network or
any other network (as the case may be). The customer shall establish and maintain appropriate measures
(such as, but not limited to, the installation of firewalls, application of authentication measures, encryption
of data, or installation of antivirus programs) to protect this product, the network, its system and
interfaces against any kind of security breaches, unauthorized access, interference, intrusion, leakage
and/or theft of data or information. ABB Inc. and its affiliates are not liable for damages and/or losses
related to such security breaches, any unauthorized access, interference, intrusion, leakage and/or theft
of data or information.
Although ABB provides functionality testing on the products and updates that it releases, the customer
should institute its own testing program for any product updates or other major system updates (to
include, but not limited to, code changes, configuration file changes, third party software updates or
patches, hardware change out) to ensure that the security measures that the customer has implemented
have not been compromised and that system functionality in the customer's environment is as expected.
Malware Prevention
Recommendation: As with any downloaded software, scan ABB embedded software packages using a
malware prevention solution.

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Safety
Read these instructions carefully before installation and commissioning. These instructions do not contain
all details on all types of products and do not explain all assembly, operating, or maintenance scenarios.
Ask the manufacturer for further information.
Observe warning signs on packaging and on the device. Safety symbols are in accordance with IEC 60417
or ISO 7000.
Assign only qualified and authorized specialists for the assembly, electrical connection, commissioning,
and maintenance of the equipment. Specialist qualifications include:
–Training or instruction and/or authorization to operate and maintain devices or systems according to
safety engineering standards for electrical circuits, high pressures, and aggressive media
–Training or instruction in accordance with safety engineering standards regarding maintenance and
use of adequate safety systems
WARNING:
According to ISO 9996, use only sufficiently insulated tools for electrical connection.
Also consider the following regulations:
–The applicable standards and safety regulations concerning the construction and operation of
electrical installations
–The regulation on technical working materials (safety guidelines for tools)
–The regulations and recommendations relating to explosion protection
–The recommendations for safe working in the case of installation in a Safety Integrity Level (SIL)
loop.
–The regulations that apply in the country of use
Potential safety hazards
The XIO uses voltages in the range of 12 - 24 Vdc plus some percent of tolerance. There are no hazardous
voltages present in the device. However, some optional power sources might convert power from Vac to -
Vdc.
Pressurized natural gas is present in the measurement pipeline. Natural gas can escape from the pipeline
during installation, calibration, or following damage to the pipeline. Only properly trained and authorized
personnel should work in hazardous locations.
WARNING – Bodily injury. Apply power only after the procedures are complete. Technicians
must perform the procedures in order: plan, install, wire, verify the power-on sequence, and
configure.
WARNING – Bodily injury. The device can be operated at high levels of pressure and with
aggressive media. Serious injury and/or considerable material damage can be caused if this
device is handled incorrectly.
WARNING – Bodily injury. Read and follow instructions contained in this guide before and
during equipment installation. Failure to do so could result in bodily injury or equipment damage.
!

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WARNING – Bodily injury. Ensure there is no hazardous atmosphere present when performing
maintenance on the unit. Do not separate components when energized. This applies to all
connectors and connections, cabling and wiring.
NOTICE
– Equipment damage or loss of data. Potential electrostatic charging hazard: clean
only with a damp cloth.
Compliance
Waste Electrical and Electronic Equipment (WEEE)
EU Directive 2012/19/EU
ABB Industrial Automation, Measurement and Analytics is committed to actively protecting the
environment. Do not dispose of WEEE as unsorted municipal waste. Collect WEEE separately. WEEE
management participation is critical to the success of WEEE collection.
Do not mix electrical and electronic equipment with general household waste if it displays the
crossed-out wheeled bin symbol. Dispose of it correctly at a recycling facility to save valuable
resources and prevent potential negative effects on health and the environment. These steps
ensure compliance with the Waste Electrical and Electronic Equipment (WEEE) Directive.
Treat waste electrical and electronic equipment (WEEE) separately. Use the national collection framework
available to customers for the return, recycling, and treatment of WEEE.
FCC RF Compliance