ELPRO 905U User manual

For 905U-C, 905U-G, 905U-K and 905U-D products,
refer to separate User Manuals
ELPRO Technologies Pty Ltd, 9/12 Billabong Street, Stafford Q 4053, Australia.
Tel: [phone] Fax: [phone] Email: [email protected]
Web: www.elprotech.com
User Manual
905U Wireless I/O Module
105S Serial I/O Module
also includes 105U 5W Wireless I/O range for licensed
frequencies in the 380 – 520 MHz band

905U Wireless I/O Module User Manual
105S Serial I/O Module
Page 2 © January 2011
Thank you for your selection of the 905U / 105S module for your I/O needs. We trust it will give you
many years of valuable service.
ATTENTION!
Incorrect termination of supply wires may
cause internal damage and will void warranty.
To ensure this product enjoys a long life,
double check ALL your connections with
the user’s manual
before turning the power on.
Caution! For continued protection against risk of fire, replace the module fuse F1 only with
the same type and rating.
CAUTION:
To comply with FCC RF Exposure requirements in section 1.1310 of the FCC Rules, antennas used
with this device must be installed to provide a separation distance of at least 33 cm from all persons
to satisfy RF exposure compliance.
DO NOT:
•operate the transmitter when someone is within 33 cm of the antenna
•operate the transmitter unless all RF connectors are secure and any open connectors are properly
terminated.
•operate the equipment near electrical blasting caps or in an explosive atmosphere
All equipment must be properly grounded for safe operations. All equipment should be serviced only
by a qualified technician.

Contents
man_905-105_2.16 Page 3
FCC Notice: 905U Wireless I/O Module
This user’s manual is for the ELPRO 905U wireless I/O module. This device complies with Part
15.247 of the FCC Rules.
Operation is subject to the following two conditions:
1) This device may not cause harmful interference and
2) This device must accept any interference received, including interference that may cause
undesired operation.
NOTE: This equipment is suitable for use in Class I Division 2 groups A, B C and D or non-hazardous
locations only
This device must be operated as supplied by ELPRO Technologies. Any changes or modifications
made to the device without the written consent of ELPRO Technologies may void the user’s authority
to operate the device.
End user products that have this device embedded must be installed by experienced radio and antenna
personnel, or supplied with non-standard antenna connectors, and antennas available from vendors
specified by ELPRO Technologies. Please contact ELPRO Technologies for end user antenna and
connector recommendations.
Notices: Safety
Exposure to RF energy is an important safety consideration. The FCC has adopted a safety standard for
human exposure to radio frequency electromagnetic energy emitted by FCC regulated equipment as a
result of its actions in Docket 93-62 and OET Bulletin 65 Edition 97-01.
FCC Notice: 105U Wireless I/O Module
Part 15 – This device has been tested and found to comply with the limits for a Class B digital
device, pursuant to Part15 of the FCC rules (Code of Federal Regulations 47CFR Part 15).
Operation is subject to the condition that this device does not cause harmful interference.
Part 90 – This device has been type accepted for operation by the FCC in accordance with Part90 of
the FCC rules (47CFR Part 90). See the label on the unit for the specific FCC ID and any
other certification designations.
Industry Canada: 105U Wireless I/O Module
RSS-119 - This device has been type accepted for operation by Industry Canada in accordance with
RSS-119 of the Industry Canada rules. See the label on the unit for the specific Industry
Canada certification number and any other certification designations.
Notice Any changes or modifications not expressly approved by ELPRO Technologies P/L could
void the user’s authority to operate this equipment.
To operate this equipment legally the user must obtain a radio operating license from the
government agency. This is done so the government can coordinate radio users in order to
minimize interference.

905U Wireless I/O Module User Manual
105S Serial I/O Module
Page 4 © January 2011
Important Notice
ELPRO products are designed to be used in industrial environments, by experienced industrial
engineering personnel with adequate knowledge of safety design considerations.
ELPRO radio products are used on unprotected license-free radio bands with radio noise and
interference. The products are designed to operate in the presence of noise and interference, however
in an extreme case, radio noise and interference could cause product operation delays or operation
failure. Like all industrial electronic products, ELPRO products can fail in a variety of modes due to
misuse, age, or malfunction. We recommend that users and designers design systems using design
techniques intended to prevent personal injury or damage during product operation, and provide
failure tolerant systems to prevent personal injury or damage in the event of product failure. Designers
must warn users of the equipment or systems if adequate protection against failure has not been
included in the system design. Designers must include this Important Notice in operating procedures
and system manuals.
These products should not be used in non-industrial applications, or life-support systems, without
consulting ELPRO Technologies first.
1. For 905U modules, a radio licence is not required in many countries, provided the module is
installed using the antenna and equipment configuration complying with the country’s
regulations.. Check with your local distributor for further information on regulations.
2. For 905U modules, operation is authorised by the radio frequency regulatory authority in your
country on a non-protection basis. Although all care is taken in the design of these units, there
is no responsibility taken for sources of external interference. The 905U intelligent
communications protocol aims to correct communication errors due to interference and to
retransmit the required output conditions regularly. However some delay in the operation of
outputs may occur during periods of interference. Systems should be designed to be tolerant of
these delays.
3. To avoid the risk of electrocution, the antenna, antenna cable, serial cables and all terminals of
the 905U/105S module should be electrically protected. To provide maximum surge and
lightning protection, the module should be connected to a suitable earth and the antenna,
antenna cable, serial cables and the module should be installed as recommended in the
Installation Guide.
4. To avoid accidents during maintenance or adjustment of remotely controlled equipment, all
equipment should be first disconnected from the 905U/105S module during these adjustments.
Equipment should carry clear markings to indicate remote or automatic operation. E.g. "This
equipment is remotely controlled and may start without warning. Isolate at the switchboard
before attempting adjustments."
5. The 905U/105S module is not suitable for use in explosive environments without additional
protection. These modules are approved for use in Class 1 Division 2 areas in North America.

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man_905-105_2.16 Page 5
Limited Lifetime Warranty, Disclaimer and Limitation of Remedies
ELPRO products are warranted to be free from manufacturing defects for the “serviceable lifetime” of
the product. The “serviceable lifetime” is limited to the availability of electronic components. If the
serviceable life is reached in less than three years following the original purchase from ELPRO,
ELPRO will replace the product with an equivalent product if an equivalent product is available.
This warranty does not extend to:
- failures caused by the operation of the equipment outside the particular product's specification, or
- use of the module not in accordance with this User Manual, or
- abuse, misuse, neglect or damage by external causes, or
-repairs, alterations, or modifications undertaken other than by an authorized Service Agent.
ELPRO’s liability under this warranty is limited to the replacement or repair of the product. This
warranty is in lieu of and exclusive of all other warranties. This warranty does not indemnify the
purchaser of products for any consequential claim for damages or loss of operations or profits and
ELPRO is not liable for any consequential damages or loss of operations or profits resulting from the
use of these products. ELPRO is not liable for damages, losses, costs, injury or harm incurred as a
consequence of any representations, warranties or conditions made by ELPRO or its representatives or by
any other party, except as expressed solely in this document..
How to Use This Manual
To receive the maximum benefit from your 905U/105S product, please read the Introduction,
Installation and Operation chapters of this manual thoroughly before putting the product to work.
Chapter Four Configuration explains how to configure the modules using the Configuration Software
available.
Chapter Five Specifications details the features of the product and lists the standards to which the
product is approved.
Chapter Six Troubleshooting will help if your system has problems and Chapter Seven specifies the
Warranty and Service conditions.
The foldout sheet Installation Guide is an installation drawing appropriate for most applications.

905U Wireless I/O Module User Manual
105S Serial I/O Module
Page 6 © January 2011
CONTENTS
CHAPTER ONE INTRODUCTION.................................................................................................. 8
1.1 GENERAL ................................................................................................................................... 8
CHAPTER TWO INSTALLATION................................................................................................ 11
2.1 GENERAL ................................................................................................................................. 11
2.2 ANTENNA INSTALLATION (905U &105U UNITS ONLY)............................................................ 11
2.2.1 Dipole and Collinear antennas............................................................................................ 13
2.2.2 Yagi antennas...................................................................................................................... 13
2.3 POWER SUPPLY........................................................................................................................ 15
2.3.1 AC Supply........................................................................................................................... 15
2.3.2 DC Supply........................................................................................................................... 15
2.3.3 Solar Supply........................................................................................................................ 16
2.3.4 Multiple Modules................................................................................................................ 17
2.3.5 24V Regulated Supply........................................................................................................ 18
2.4 INPUT /OUTPUT ....................................................................................................................... 18
2.4.1 Digital Inputs (905-1, 905-2 and 905-4)............................................................................. 18
2.4.2 Digital Outputs (905-1)....................................................................................................... 18
2.4.3 Digital Outputs (905-2, 905-3 and 905-4) .......................................................................... 19
2.4.4 Analog Inputs (905-1 and 905-2)........................................................................................ 19
2.4.5 Analog Outputs (905-1 and 905-3)..................................................................................... 21
2.4.6 Pulse Input (905-1) ............................................................................................................ 23
2.4.7 Pulse Inputs (905-2 and 905-4).......................................................................................... 23
2.4.8 Pulse Output (905-1)........................................................................................................... 24
2.4.9 Pulse Output (905-3 and 905-4).......................................................................................... 24
COUNT+........................................................................................................................................ 24
2.4.10 RS232 Serial Port............................................................................................................ 25
2.4.11 RS485 Serial Port............................................................................................................ 25
2.4.12 Connecting 105S Modules to 905U Modules................................................................. 26
CHAPTER THREE OPERATION.................................................................................................. 27
3.1 POWER-UP AND NORMAL OPERATION...................................................................................... 27
3.1.1 Communications ................................................................................................................. 27
3.1.2 Change of state conditions.................................................................................................. 29
3.1.3 Analog Set-points................................................................................................................ 32
3.1.4 Start-up Poll ........................................................................................................................ 32
3.1.5 Communications Failure (CF) ............................................................................................ 32
3.1.6 Resetting Outputs................................................................................................................ 33
3.2 SYSTEM DESIGN TIPS............................................................................................................... 33
3.2.1 System Dynamics................................................................................................................ 33
3.2.2 Radio Channel Capacity ..................................................................................................... 33
3.2.3 Radio Path Reliability......................................................................................................... 34
3.2.4 Design for Failures.............................................................................................................. 34

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man_905-105_2.16 Page 7
3.2.5 Indicating a Communications Problem............................................................................... 35
3.2.6 Testing and Commissioning................................................................................................ 36
3.3 SECURITY CONSIDERATIONS.................................................................................................... 36
CHAPTER FOUR CONFIGURATION.......................................................................................... 37
4.1 INTRODUCTION ........................................................................................................................ 37
4.2 EASY CONFIGURATION USING DEFAULT SETTINGS ................................................................. 38
4.3 CONFIGURATION SOFTWARE.................................................................................................... 40
4.3.1 Hardware and Software Requirements ............................................................................... 40
4.3.2 Program Operation.............................................................................................................. 40
4.3.4 Loading Configuration from a Module............................................................................... 52
4.3.5 Modifying and Archiving Configuration Files ................................................................... 52
4.3.6 Print Options....................................................................................................................... 53
4.3.7 Security ............................................................................................................................... 53
4.3.8 Using 105S Modules........................................................................................................... 55
CHAPTER FIVE SPECIFICATIONS............................................................................................. 58
5.1 DIMENSIONED DRAWING ......................................................................................................... 61
CHAPTER SIX TROUBLESHOOTING ....................................................................................... 63
6.1 DIAGNOSTICS CHART............................................................................................................... 63
6.2 SELF TEST FUNCTIONS............................................................................................................. 64
6.2.1 Input to Output Reflection (905U-1/105S-1 only)............................................................. 64
6.2.2 Radio Testing using Tone Reversals (105U/905U modules only) ..................................... 64
6.2.3 Diagnostics menu................................................................................................................ 64
6.2.4 Comms Logging.................................................................................................................. 71
6.3 RADIO PATH TESTING.............................................................................................................. 73
CHAPTER SEVEN WARRANTY & SERVICE............................................................................ 75
APPENDIX A SYSTEM EXAMPLE........................................................................................... 76
APPENDIX B TERMINAL LAYOUTS .......................................................................................... 82

905U Wireless I/O Module User Manual
105S Serial I/O Module
Page 8 © January 2011
Chapter One INTRODUCTION
1.1 General
The 905U, 105U & 105S range of I/O modules has been designed to provide standard “off-the-shelf”
telemetry functions, for an economical price. Telemetry is the transmission of signals over a long
distance via a medium such as radio or twisted-pair wire. Although the 905U/105S is intended to be
simple in its application, it also provides many sophisticated features. This manual should be read
carefully to ensure that the modules are configured and installed to give reliable performance.
The unit can monitor and control the following types of signals:
Digital on/off signals
Example outputs - motor run, siren on
Example inputs - motor fault, tank overflow, intruder alarm
Analog continuously variable signals (0-20mA)
Example outputs - tank level indication, required motor speed
Example inputs - measured tank level, actual motor speed
Pulse frequency signals
Examples - electricity metering, fluid flow
Internal Status signals
Examples - analog battery voltage, power status, solar panel status and low battery
status.
The unit will monitor the input signals and transmit the signal information by radio or RS485 twisted
pair to another module or modules. At the remote unit, the signals will be reproduced as digital,
analog or pulse output signals. The modules also provide analog set points, so that a digital output may
be configured to turn on and off depending on the value of an analog input. The pulse I/O transmits an
accumulated value and the pulses are reliably recreated at the remote unit regardless of ‘missed’
transmissions. The actual pulse rate is also calculated and is available as a remote analog output.
This manual covers the 905U, 105U and 105S modules. We have provided a summary on all products
available in the range, below.
•905U-1, 905U-2, 905U-3 and 905U-4 modules have radio and serial communications. The
modules differ only in their input/output (I/O) design, and are compatible, i.e. they can be used to
communicate signals to each other in the same network. The 905U has a frequency hopping spread
spectrum 900MHz radio which is license-free in many countries.
•105U-1, 105U-2, 105U-3 and 105U-4 modules are similar to the 905U range, except they have a
fixed frequency radio in the 380 – 520MHz band (configurable 0.5 – 5W RF power), suitable for

Chapter One Introduction
man_905-105_2.16 Page 9
licensed radio channels in most countries.
•105S-1, 105S-2, 105S-3 and 105S-4 modules have only serial communications. All other
specifications are as per the 905U-1, 2, 3 & 4 modules. The 105S modules are compatible with
905U modules. 105S modules may be used for serial I/O applications, or as I/O expansion for
905U modules.
•The 905U-C and 905U-G modules provides an interface between host devices such as PLC’s or
SCADA computers, and a wireless I/O system comprising 905U modules. The 905U-C and 905U-
G allows 905U modules to act as remote wireless I/O for the host devices. For more information,
refer to the 905U-C or 905U-G User Manual.
The 905U radio has been designed to meet the requirements of unlicensed operation for remote
monitoring and control of equipment. That is, a radio licence is not required for the 905U modules in
many countries. See Chapter Five Specifications for details. The 105U radio is suitable for fixed
frequency licensed channels in the 380-520MHz band -that is, a radio license is required to use the
105U products, but not the 905U products.
I/O Types
905U-1
105U-1
105S-1
905U-2
105U-2
105S-2
905U-3
105U-3
105S-3
905U-4
105U-4
105S-4
Radio 
Serial 
Digital
Inputs (DI) 4 4 4 to 16
Digital
Outputs (DO) 4 (relay) 1 (FET) 8 (FET) 4 to 16 (FET)
Analog
Inputs (AI) 2 (4-20mA) 6 (0-20mA)
Analog
Outputs (AO) 2 (4-20mA) 8 (0-20mA)
Pulse Inputs
(PI) 1 (100Hz) 4 (1x1KHz,
3x100Hz) 4 (1x1KHz, 3x100Hz)
Pulse
Outputs (PO) 1 (100Hz) 4 (100 Hz) 4 (100 Hz)
Comments PI is DI 1. PO is
separate to DO. PI’s are the same as DI’s. PO’s are the same as DO’s . PI/ PO’s are the same as DI/ DO’s.
Note regarding -4 modules. The 905U/105S-4 has a total of 20 digital I/O. Four are fixed inputs
(also PI’s) and four are fixed outputs (also PO’s). The other 12 are selectable individually as DI or
DO. The I/O range can vary from 16DI + 4DO to 4DI + 16DO or any combination in between.

905U Wireless I/O Module User Manual
105S Serial I/O Module
Page 10 © January 2011
Input signals connected to a module are transmitted to another module and appear as output signals.
These input signals may also be configured to appear as “inverted” signals on the output. A
transmission occurs whenever a "change-of-state" occurs on an input signal. A "change-of-state" of a
digital or digital internal input is a change from "off" to "on" or vice-versa. A "change-of-state" for an
analog input, internal analog input or pulse input rate is a change in value of the signal of 3%
(configurable from 0.8 to 75 %).
In addition to change-of-state messages, update messages are automatically transmitted on a regular
basis. The time period may be configured by the user for each input. This update ensures the integrity
of the system.
Pulse inputs are accumulated as a pulse count and the accumulated pulse count is transmitted regularly
according to the configured update time.
The I/O modules transmit the input/output data as a data frame using radio or serial RS485 as the
communications medium. The data frame includes the "address" of the transmitting module and the
receiving module, so that each transmitted message is acted on only by the correct receiving unit. Each
transmitted message also includes error checking to ensure that no corruption of the data frame has
occurred due to noise or interference. The module with the correct receiving "address" will
acknowledge the message with a return transmission. If the original module does not receive a correct
acknowledgement to a transmission, it will retry up to five times before setting the communications fail
status of that path. In critical paths, this status can be reflected on an output on the module for alert
purposes. The module will continue to try to establish communications and retry, if required, each time
an update or change-of-state occurs.
A system may be a complex network or a simple pair of modules. An easy-to-use configuration
procedure allows the user to specify any output destination for each input.
The maximum number of modules in one system is 95 modules communicating by radio. Each of
these modules may have up to 31 other modules connected by RS485 twisted pair. Modules may
communicate by radio only, by RS485 only or by both RS485 and radio. Any input signal at any
module may be configured to appear at any output on any module in the entire system.
Systems with a 905U-C or 905U-G module and host device can have more than 95 radio modules.
Modules can be used as repeaters to re-transmit messages on to the destination module. Repeaters can
repeat messages on the radio channel, or from the radio channel to the serial channel (and serial to
radio). Up to five repeater addresses may be configured for each input-to-output link.
The units may be configured by using a PC connected to the RS232 port. The default configuration
and software configuration is defined in Section 4 Configuration.
Note: In this manual, reference to the 905U Wireless I/O units also relates to the 105U
Wireless I/O units.