FreeWave FGRIO-M User manual

FGRIO System User Manual
Version 1
FGRIO Master
FGRIO-M FGRIO Slave FGRIO-S FGR2-IO Slave FGR2-IOS-CE-U
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UL Notification:
This equipment is suitable for use in Class I, Division 2, Groups A, B, C, and D or non-
hazardous locations only.”
Warning—Explosion Hazard—Substitution of components may impair suitability for
Class I, Division 2.
The diagnostics port and cable do not have a latching connector and cannot be
used in a hazardous location.
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Table of Contents
Description…………………………………………………………….….……….…………...5
Glossary …………………………………………………….….…………………………..5-6
Diagrams …..………………………………………….….……………………………...….7-8
LEDs ………………………………………………….….………………………...…………9
Set Up with Hyperterminal…..…………..………….…..……………...……………...….9-17
FGRIO Master………………………………..………....…………………………9-13
Operation Mode ………………………….…………….……………………..9
Call Book ..……...……………………………..………………….………...10
Radio Transmission Characteristics..……….…..……………….…………10
Max and Min Packet Sizes ………………...………………………...10
RF Data Rate ……………………...………………………………….10
Multipoint Parameters …………………...………………………………....10
Number of Repeaters……………...……………………………….....10
Network ID ………………………………………………………...….10
FGRIO Setup ...………………..…………………………………...……..11-13
IO Slave………………………………………….……………….……………….14-17
Operation Mode ………….………………………………………………….14
Call Book ……...……………………………………………………………..14
Radio Transmission Characteristics …………….………….……..……14-15
Max and Min Packet Sizes ……………………………………….14-15
RF Data Rate ………………………….………………………..…….15
Retry Timeout ………………………..………………………….……15
Multipoint Parameters ……………………..………………………….…….15
Number of Repeaters ………………..…………………….………….15
Network ID …………………………..………………………………..15
FGRIO Setup………………………..……………………...….……….....16-17
Set Up with Tool Suite………..…………..………..……………………………...………18-26
FGRIO Master…………………………..……………………………………..….18-21
Operation Mode ………………..……………………………………….…....18
Call Book……………………………………..……………………………….18
Radio Transmission Characteristics …………..…………………..…….….19
Max and Min Packet Sizes …………….……...……………………...19
RF Data Rate ……………………….………...……………………….19
Multipoint Parameters…………………………………...………………19-20
Number of Repeaters…………………………………...…………….19
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Table of Contents
Network ID…………………………………………………...……….19
IO Settings……………………………………………………...………...20-21
Enable FGRIO……………………………………………...……….. 20
Mapping……………………………………………….……...……….20
Time Out ……………………………………………..…...…………..21
Sensor Power………………………………………...………….…….21
IO Slave……………………………………………,,,…………………………….22-26
Operation Mode……….………………………...……………………..…….22
Call Book…………………………………...………………………………...22
Radio Transmission Characteristics………………….…………...………..23
Max and Min Packet Sizes ……………...……….………...………...23
RF Data Rate ……………………………………………...………….23
Retry Timeout ………………………………………..…..…………..23
Multipoint Parameters………………………………………..………….….24
Number of Repeaters………………………..……………..….……...24
Network ID……………………………………..………...…………...24
Wire Replacement…………………………………….………………….25-26
Digital Out 1 and Digital Out 2……………………….……………...25
Digital Def 1 and Digital Def 2……………………….………………25
Default Delay………………………………………………………….25
Digital Input Pull Up/Down…………………………….……...……..25
Installation………….…………………………………….……………………………….26-34
IO Slave……………………………………………..………………………...…..26-32
B+ …………………………………………… …………….……….……….26
1-5 Volt Sensor ……………………………..……………………………26-27
4-20 Milliamp Sensor …………………………………………… ….….27-28
1-5 Volt Sensor, Analog Input 3 or Analog Input 4…….…… …..…...28-30
Signal Levels and Accuracy……………………… ………...…......28
Signal Coupling for Analog Input 3 and Analog Input 4 ...…29-30
4-20 Milliamp Sensor, Analog Input 3 or Analog Input 4…… ……...30-31
Digital Input …………………………………….…………………..32
Digital Output …………………………… …..……………………………32
FGRIO Master ……………………………………..…… …………………….33-34
Rx, Tx, B+ ……………………………… …...…………………………..33
Analog Output ..….……………………………..………… ………………33
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Table of Contents
Digital Output …………………………………………….…………………33
Digital Input …………………………………….……………….………….23
Sensor Power………………………..……………………………………33-34
Link Alarms ………………………………………………………..………..34
Frequently Asked Questions ... …….……………………………….……….……….…34-35
Wiring Diagram …………………………………………………………………………….36
Specifications …………………………...……………………………………………….27-39
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Description
This is an addendum to the Spread Spectrum Wireless Data Transceiver User Manual. It covers
details applicable specifically to using the FreeWave FGRIO Master and Slave modems. Please
use this addendum in conjunction with the User Manual.
The FreeWave Technologies FGRIO System provides outstanding performance and versatility
in wireless transmission of process-control signals. FGRIO offers “transparent” acquisition,
transport and reconstruction of analog, digital and power signals, eliminating the need for asso-
ciated buried wiring. The RTU requires no altered programming. The FGRIO is Class 1 Div 2
approved and is lower-cost and provides better signal integrity than vulnerable wiring.
The FGRIO System is based upon wireless RF Technologies. RF is subject to interference and
communication interruptions. It should not be expected, therefore, to provide 100% communi-
cation, 100% of the time. The FGRIO System should not be used without proper provisions to
ensure safety upon loss of radio communications.
Glossary
FGRIO Master– FreeWave wireless radio transceiver that operates as a Master for up to 4
FGRIO or FGR2-IO Slaves, and can operate as a Slave in a point to multipoint network. The
FGRIO Master can receive over air a total of 4 analog input signals and 4 digital input signals
from up to 4 FGRIO or FGR2-IO Slaves. It can also transmit up to 4 digital output signals
over air to the FGRIO or FGR2-IO Slaves. The FGRIO Master does not operate as a Slave/
Repeater in the SCADA system.
FGRIO Slave – FreeWave wireless radio transceiver that accepts up to a total of 4 input signals
from sensors, then transmits these signals over air to the FGRIO Master. Two of the 4 available
input signals can only be transmitted as analog signals and are labeled as Analog Input 1 and
Analog Input 2 on the Slave’s terminal block. The other two input signals may be either analog
or digital inputs, depending on the user’s needs. The FGRIO Slave can also receive over air 2
digital output signals and a sensor power control signal from the FGRIO Master.
FGR2-IO Slave – New generation FreeWave wireless radio transceiver that accepts up to a to-
tal of 4 input signals from sensors, then transmits these signals over air to the FGRIO Master.
Two of the available 4 input signals can only be transmitted as analog signals and are labeled as
Analog Input 1 and Analog Input 2 on the Slave’s terminal block. The other two input signals
may be either analog or digital inputs, depending on the user’s needs. The FGR2-IO Slave can
also receive over air 2 digital output signals and a sensor power control signal from the FGRIO
Master. The FGR2-IO has a line-of-sight range of 60 miles, compared to the 2 mile line-of-
sight range of the FGRIO Slave.
A note about terminology: The phrase ‘FGRIO System’, when used in this manual, will refer
to any system that uses an FGRIO Master in conjunction with either FGRIO or FGR2-IO
Slaves. IO Slave will refer to either an FGRIO Slave or an FGR2-IO Slave.
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Glossary (cont.)
Analog Circuit– An electronic circuit that operates with currents and voltages that vary continu-
ously with time and have no abrupt transitions between levels. Temperatures, pressures, or flow
rates are all represented by analog circuits.
Digital Circuit– An electronic circuit that functions as though currents or voltages exist only at
one of a set of discrete levels, all transitions between levels being ignored. The states of a digital
circuit are often referred to as on or off, high or low.
VSNS- This is screw terminal # 7 on the IO Slave. This is an output used to power sensors/
transmitters. The maximum output voltage of this terminal is 20VDC for the FGRIO-S and
30VDC for the FGR2-IOS-C-U and FGR2-IOS-CE-U
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10 pin HeaderTerminal Block
FGRIO Master
Terminal Block
• Sensor Power
• Digital Input 1
• Digital Input 2
• Digital Input 3
• Digital Input 4
• Analog Output 1
• Analog Output 2
• Analog Output 3
• Analog Output 4
• Digital Output 1
• Digital Output 2
• Digital Output 3
• Digital Output 4
• Link Alarm
• CMD Alarm
• Not Used
Ground
Rx Data
Tx Data
B+ In
Diagrams
Fig. 1
Fig. 2
• Sensor Power
• Digital Input 1
• Digital Input 2
• Digital Input 3
• Digital Input 4
• Analog Output 1
• Analog Output 2
• Analog Output 3
• Analog Output 4
• Digital Output 1
• Digital Output 2
• Digital Output 3
• Digital Output 4
• Link Alarm
• CMD Alarm
• Not Used
• Sensor Power
• Digital Input 1
• Digital Input 2
• Digital Input 3
• Digital Input 4
• Analog Output 1
• Analog Output 2
• Analog Output 3
• Analog Output 4
• Digital Output 1
• Digital Output 2
• Digital Output 3
• Digital Output 4
• Link Alarm
• CMD Alarm
• Not Used
Diagnostic Port
FGRIO Master Layer
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Fig. 3
Fig. 4
Diagrams (cont.)
Note: *Analog Output 2 is not available in the IO Wire Replacement mode. Analog Inputs 3 and 4 are 0-
3.3VDC inputs. See wiring diagrams on pages 29-31 for details.
FGR2-IO Slave
Terminal Block
• 12-Ground
• 11-B+ IN
• 10-Analog Input 2
• 9-Ground
• 8-Analog Input 1
• 7-VSNS/Analog Out 1
• 6-Analog Output 2*
• 5-Digital Output 2
• 4-Digital Output 1
• 3-Ground
• 2-Digital Input 2 OR
Analog Input 4*
• 1-Digital Input 1 OR
Analog Input 3*
• 12-Ground
• 11-B+ IN
• 10-Analog Input 2
• 9-Ground
• 8-Analog Input 1
• 7-VSNS/Analog Out 1
• 6-Ground
• 5-Digital Output 2
• 4-Digital Output 1
• 3-Ground
• 2-Digital Input 2 OR
Analog Input 4*
• 1-Digital Input 1 OR
Analog Input 3*
FGRIO Slave
Terminal Block
Diagnostics Port 10 Pin Header
Pin #1
Terminal Block
Connector
Terminal Block
Connector
Pin #1
DB9 Data port
Diagnostics Port
FGRIO/FGR2-IO Slave FGR2-IO-CE-U
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Set Up with HyperTerminal
FGRIO Master– In order for the FGRIO System to function properly, the following settings
must be programmed. For all other settings not listed below, please refer to the User Manual.
(0) Operation Mode
(3) Point to MultiPoint Slave– Choose this setting when the FGRIO System is being inte-
grated into an FGR Serial Network. The IO functionality is turned on in Menu 9–
FGRIO Set Up, in HyperTerminal.
Note: Setting (E), FGRIO Master, should only be selected when the FGRIO System is operating inde-
pendently of an FGR FreeWave Network.
LEDs
The LEDs should have the following appearance when the IO Slave is linked to the FGRIO Master in a FGRIO
Stand Alone Network:
FGRIO Master FGRIO Slave
Carrier Detect
(CD) Transmit (TX) Clear to Send (CTS) Carrier De- tect (CD) Transmit (TX) Clear to Send (CTS)
Solid green
bright Solid red dim FLICKERING red Blinking green Blinking red Blinking red
The LEDs on the FGRIO Master and IO Slave should have the following appearance when the FGRIO Master is
linked to the FGR Network Master and the IO Slave is linked to the FGRIO Master:
FGRIO Master FGRIO Slave
Carrier Detect
(CD) Transmit (TX) Clear to Send (CTS) Carrier De- tect (CD) Transmit (TX) Clear to Send (CTS)
Solid green
bright Solid red dim BLINKING red Blinking green Blinking red
Blinking red
Fig. 5
Use this Operation Mode when the
FGRIO Master is being integrated into
an FGR Serial Network
Use this Operation Mode when the
FGRIO System is Stand Alone
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Set Up with HyperTerminal (cont.)
FGRIO Master
(2) Call Book– IO Slaves’ serial numbers must be programmed in the FGRIO Master’s Call
Book. In addition, the Network ID must be set to the same ID as the rest of the network.
Programming both the Call Book and Network ID settings is unique to the FGRIO System
and must be done for both integrated and stand alone applications.
(3) Radio Transmission Characteristics
(1) Max Packet Size and (2) Min Packet Size– The FGRIO System requires a minimum
combined packet size of 48 Bytes. The following is a list of the available packet sizes that can
be used.
(4) RF Data Rate– The RF Data Rate must be set to 3 when using the FGRIO System. This
is for applications that are stand alone or when integrated into an existing FGR network.
MultiPoint Parameters-
(0) Number Repeaters– This setting must be set to 1 for all FGR and IO radios in the
Network.
(6) Network ID– In addition to entering the IO Slaves’ serial numbers in the Call
Book, the Network ID being used for the Network must be set from 1-4095. (Do NOT
use 255). Programming both the Call Book and Network ID settings is unique to the
FGRIO System and must be done for both integrated and stand alone applications.
Note: The FGRIO Master does not function as a Slave/Repeater in the SCADA network.
Combined Packet Size Definition with RF Date Rate of 3
Max Setting
Min Setting 0123456789
08 24 40 56 72 88 104 120 136 152
112 28 44 60 76 92 108 124 140 156
216 32 48 64 80 96 112 128 144 160
320 36 52 68 84 100 116 132 148 164
424 40 56 72 88 104 120 136 152 168
528 44 60 76 92 108 124 140 156 172
632 48 64 80 96 112 128 144 160 176
736 52 68 84 100 116 132 148 164 180
840 56 72 88 104 120 136 152 168 184
944 60 76 92 108 124 140 156 172 188
Fig. 6
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Set Up with HyperTerminal (cont.)
FGRIO Master
(9) FGRIO Setup– Outputs on the FGRIO Master are mapped to inputs on the IO Slave.
Fig. 7
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Set Up with HyperTerminal (cont.)
FGRIO Master
(9) FGRIO Setup (cont.)
(0) FGRIO – Must be set to 1 to enable I/O functions.
(1) to (8) – To map the FGRIO Master outputs to the correct IO Slave inputs, use
the following steps:
1) Select which IO Slave you are mapping to the FGRIO Master. Note the Master’s
Call Book Entry # that lists this IO Slave’s serial number.
2) Next, determine which analog or digital input from the IO Slave radio you wish to
map to the FGRIO Master. This could be Analog Input(AI)#1, AI#2, AI#3, AI#4, or
Digital Input(DI)#1, or DI#2, depending on which sensor(s) the Slave will be con-
nected to.
3) Using the following table, find the intersection between the Master’s Call Book
Entry # (found in step 1) and the selected input from the Slave (found in step 2).
Note the number listed at this intersection.
4) Go to Menu 9, FGRIO Setup (Figure 7). Select which Master’s output you would
like to “connect” to the input from the Slave. At the flashing curser, enter the number
to the left of the selected output. Next enter the number found in step 3. This num-
ber should be displayed to the right of the selected output.
Fig. 8
AI#1 AI#2 AI#3 AI#4 DI#1 DI#2
FRGIO-M Call Book
Entry #0 1 2 9 10 1 2
FRGIO-M Call Book
Entry #1 3 4 11 12 3 4
FRGIO-M Call Book
Entry #2 5 6 13 14 5 6
FRGIO-M Call Book
Entry #3 7 8 15 16 7 8
EXAMPLE
To map Analog Output 1 of the FGRIO Master to Analog Input 2 of the IO Slave (serial # 930-
0004), entry (5) in the FGRIO Setup menu will have a value of 2. This is calculated by first
checking the Call Book entry # of IO Slave #930-0004 (See Figure 9, next page). The entry # is
0. Next, go to the table above, find call book entry # 0, then go to the column for IO Slave Ana-
log Input #2. The value listed is 2. A 2 will be entered for Analog Output #1 of the FGRIO
Master.
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Fig. 9
(9) FGRIO Setup (cont.)
(9) TimeOut– 0-255. This setting determines the amount of time to wait before issuing a
Link Alarm due to loss of communication between the FGRIO Master and IO
Slave. A setting of 1 = 1/6 second
6 = 1 second
42 = 7 seconds
252 = 42 seconds
(A) Sensor Power– 0 or 1. A setting of 0 supplies continuous power to the sensor at the
IO Slave. A setting of 1, “Gated”, is used when the RTU provides a switched
power output to control powering the sensors at the IO Slave and analog outputs of
the FGRIO Master on and off.
Set Up with HyperTerminal (cont.)
FGRIO Master
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Set Up With HyperTerminal (cont.)
IO Slave- In order for the FGRIO System to function properly, the following settings must be
programmed. For all other settings not listed below, please refer to the User Manual.
(0) Operation Mode
(E) FGRIO Slave
(2) Call Book– The FGRIO Master’s serial number must be programmed as entry #0 in the IO
Slave’s Call Book. Set “Entry to Call” to 0. In addition, the Network ID must be set to the
same ID as the rest of the network. Programming both the Call Book and Network ID set-
tings is unique only to the FGRIO System and must be done for both integrated and stand
alone applications.
(3) Radio Transmission Characteristics
(1) Max Packet Size and (2) Min Packet Size– The FGRIO System requires a minimum
combined packet size of 48 Bytes. The following is a list of the available packet sizes
that can be used (Figure 11, next page).
Fig. 10
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Set Up with HyperTerminal (cont.)
IO Slave
(3) Radio Transmission Characteristics (cont.)
(4) RF Data Rate– The RF Data Rate must be set to 3 when using the FGRIO System. This
is for applications that are stand alone or when integrated into an existing FGR network.
(8) Retry Timeout– By lowering the Retry Timeout, the inactive link time between the
FGRIO Master and IO Slave can be reduced when going from autonomous mode to
connecting back to the FGR Network. If the Network Master goes down, the FGRIO
Master and Slave will continue to operate in autonomous mode. When the Network
Master comes back up, the FGRIO Master will break the link with the IO Slave to
reestablish a link with the Network Master. Once the FGRIO Master is linked to the
Network Master, then the IO Slave will be able to link back to the FGRIO Master.
With a lower Retry Timeout setting, it will take less time for the IO Slave to link to
the FGRIO Maser.
(5) MultiPoint Parameters-
(0) Number Repeaters- This setting must be set to 1 for all FGR and IO radios in the
Network.
(6) Network ID– In addition to entering the FGRIO Master’s serial number in the Call
Book, the Network ID being used for the Network must be set from 1-4095 (Do NOT use
255). Use the same Network ID for the IO Slave as was used for the FGRIO Master.
Programming both the Call Book and Network ID settings is unique to the FGRIO
System and must be done for both integrated and stand alone applications.
Combined Packet Size Definition with RF Date Rate of 3
Max Setting
Min Setting 0123456789
08 24 40 56 72 88 104 120 136 152
112 28 44 60 76 92 108 124 140 156
216 32 48 64 80 96 112 128 144 160
320 36 52 68 84 100 116 132 148 164
424 40 56 72 88 104 120 136 152 168
528 44 60 76 92 108 124 140 156 172
632 48 64 80 96 112 128 144 160 176
736 52 68 84 100 116 132 148 164 180
840 56 72 88 104 120 136 152 168 184
944 60 76 92 108 124 140 156 172 188
Fig. 11
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IO Slave
(9) FGRIO Setup
(0) Default Delay, the value set is in .28 second units. This sets the time duration that will
pass, after a loss of communication, before the radio enters default condition. e.g. A value of
36 = 36*0.28 seconds = 10.08 seconds.
(1) Digital Out1– Select the desired FGRIO Master Digital Input # (1-4) to control the
IO Slave Digital Output # 1.
(2) Digital Out2– Select the desired FGRIO Master Digital Input # (1-4) to control the
IO Slave Digital Output # 2.
(3) Digital Def 1 – Select the desired IO Slave Output Default at power-on and link failure.
0= Open Drain output ON (Conducting to GND, 2 Amps max)
1= Open Drain output OFF (Non-Conducting)
2= Make no change in state.
(4) Digital Def2- Select the desired IO Slave Output Default at power-on and link failure.
0= Open Drain output ON (Conducting to GND, 2 Amps max)
1= Open Drain output OFF (Non-Conducting)
2= Make no change in state.
Note: If programming a DO to turn on after loss of link, ensure that the energized device
can sustain the state undamaged in case the loss in lengthy.
(5) IO Modbus– This menu option must be set to “Disabled” when using a FGRIO network
configuration.
(E and F) DI1 Pull Up/Down- Options E and F control power-up states of the internal resis-
tor (10Kohms) connected to the DIs. They can pull up, such as when using a closed-contact-
to-GND switch input, pull down so that unused inputs read “0” as DIs or ~0 as auxiliary ana-
logs, or float to not load analog inputs.
(I and J) AI(DI1) and AI(DI2) Filter do not apply in the FGRIO network.
Note: Both of the IO Slave Digital Outputs may be driven by the same FGRIO
Master Input.
Set Up with HyperTerminal (cont.)
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Fig. 12
Set Up with HyperTerminal (cont.)
(9) FGRIO Setup (cont.)
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Set Up with Tool Suite
FGRIO Master– In order for the FGRIO System to function properly, the following settings
must be programmed. For all other settings not listed below, please refer to the User Manual.
0) Set Operation Mode Tab-(Figure 13)
Point to MultiPoint Slave– Choose this setting when the FGRIO System is being inte-
grated into an FGR FreeWave Network. The IO functionality is turned on under the IO Set-
tings tab.
Note: Setting (E), FGRIO Master, should only be selected when the FGRIO System is operating inde-
pendently of an FGR FreeWave Network.
Figure 13
2) Call Book Tab-
Enter the serial number for each IO Slave, for a maximum of up to four (4) IO-Slave Ra-
dios.
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3) Radio Transmission Characteristics Tab-(Figure 14)
Max Packet Size and Min Packet Size– The FGRIO System requires a minimum com-
bined packet size of 48 Bytes. See Figure 6 (pg. 10) for a list of available packet sizes.
RF Data Rate– The RF Data Rate must be set to “Normal” (3) when using the FGRIO Sys-
tem. This is for applications that are stand alone or when integrated into an existing FGR
network.
Set Up with Tool Suite (cont.)
Figure 14
5) MultiPoint Parameters Tab– (Figure 15)
Number Repeaters– This setting must be set to 1 for all FGR and FGRIO radios in the
Network.
Network ID– In addition to entering the serial numbers of the IO Slaves in the Call Book,
the Network ID being used for the Network must be set from 1-4095 (Do NOT use 255).
Programming both the Call Book and Network ID settings is unique to the FGRIO System
and must be done for both integrated and stand alone applications.
Note: The FGRIO Master does not function as a Slave/Repeater in the SCADA network.
Figure 14
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