Hitachi HX-RIO3 Series User manual

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HX-RIO3 Series
MODBUS RTU Network Adapter Light
RIO3-MBRL
User manual

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HX-RIO3 Series
DOCUMENT CHANGE SUMMARY
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REMARKS
DATE
EDITOR
1.00
New Document
Feb 2021
Faber

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HX-RIO3 Series
Contents
1. Important Note ..........................................................................................................................5
1.1. Safety Instruction...................................................................................................................6
1.1.1. Symbols...............................................................................................................................6
1.1.2. Safety Notes........................................................................................................................6
1.1.3. Certification.........................................................................................................................6
2. Specification..............................................................................................................................7
2.1. Interface..................................................................................................................................7
2.1.1. RIO3-MBRL..........................................................................................................................7
2.2. Specification...........................................................................................................................8
2.2.1. General Specification..........................................................................................................8
2.2.2. Interface Specification........................................................................................................9
2.3. LED Indicator........................................................................................................................10
2.3.1 MOD (Module Status LED).................................................................................................10
2.3.2 RXD (Receive Data LED)....................................................................................................10
2.3.3 TXD (Transmit Data LED)...................................................................................................10
2.3.4 IOS LED (Extension Module Status LED).........................................................................10
3. Dimension ...............................................................................................................................11
3.1. RIO3-MBRL...........................................................................................................................11
4. Mechanical Set Up ..................................................................................................................12
4.1. Total Expansion ...................................................................................................................12
4.2. Plugging and Removal of the Components .......................................................................12
5. MODBUS Electrical Interface .................................................................................................12
5.1. G-Bus System ......................................................................................................................14
5.3. RIO3-MBRL Electrical Interface...........................................................................................16
5.3.1. RJ-45 Socket .....................................................................................................................16
5.3.2. MODBUS Dip Switch Setup..............................................................................................16
5.3.3. Process Image Map...........................................................................................................17
5.3.4. MODBUS Interface Register/Bit Map ...............................................................................17
5.4. Example................................................................................................................................18
5.4.1. Example of Input Process Image (Input Register) Map..................................................18
5.4.2. Example of Output Process Image (Output Register) Map ............................................19
6. MODBUS TCP/UDP INTERFACE............................................................................................20
6.1 MODBUS TCP/ UDP Protocol...............................................................................................20

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HX-RIO3 Series
6.1.1. Comparison of MODBUS TCP/UDP and MODBUS/RTU .................................................20
6.1.2. MODBUS TCP/ UDP MBAP Header..................................................................................21
6.2 Supported MODBUS Function Codes..................................................................................21
6.2.1. 1(0x01) Read Coils ............................................................................................................22
6.2.2. 2(0x02) Read Discrete Inputs ...........................................................................................22
6.2.3. 3(0x03) Read Holding Registers.......................................................................................23
6.2.4. 4 (0x04) Read Input Registers..........................................................................................23
6.2.5. 5 (0x05) Write Single Coil .................................................................................................24
6.2.6. 6 (0x06) Write Single Register..........................................................................................25
6.2.7. 8 (0x08) Diagnostics .........................................................................................................25
6.2.8. 15 (0x0F) Write Multiple Coils...........................................................................................27
6.2.9. 16 (0x10) Read/Write Multiple Registers..........................................................................28
6.2.10. 23 (0x17) Read/Write Multiple Registers........................................................................29
6.2.11 Error Response................................................................................................................29
6.3 MODBUS Special Register Map ...........................................................................................30
6.3.1 Adapter Identification Special Register (0x1000, 4096)...................................................30
6.3.2 Adapter Watchdog Time, other Time Special Register (0x1020, 4128)...........................31
6.3.3 Adapter Information Special Register (0x1100, 4352)......................................................31
6.3.4 Expansion Slot Information Special Resister (0x2000, 8192)..........................................33
6.4. MODBUS Reference.............................................................................................................34
7. Troubleshooting......................................................................................................................35
How to diagnose by LED indicator............................................................................................35
How to diagnose when device couldn't communicate network ..............................................36
A.1 Product List ..........................................................................................................................37
A.2. Glossary...............................................................................................................................38

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HX-RIO3 Series
1. Important Note
Solid state equipment has operational characteristics differing from those of electromechanical equipment.
Safety Guidelines for the Application, Installation and Maintenance of Solid-State Controls describes some
important differences between solid state equipment and hard-wired electromechanical devices.
Because of this difference, and also because of the wide variety of uses for solid state equipment, all persons
responsible for applying this equipment must satisfy themselves that each intended application of this
equipment is acceptable.
In no event will HITACHI be responsible or liable for indirect or consequential damages resulting from the use
or application of this equipment.
The examples and diagrams in this manual are included solely for illustrative purposes. Because of the many
variables and requirements associated with any installation, HITACHI cannot assume responsibility or liability
for actual use based on the examples and diagrams.
✓If you don't follow the directions, it could cause a personal injury, damage to the equipment or
explosion
⚫Do not assemble the products and wire with power applied to the system. Else it may cause an
electric arc, which can result into unexpected and potentially dangerous action by field devices. Arching is
explosion risk in hazardous locations. Be sure that the area is non-hazardous or remove system power
appropriately before assembling or wiring the modules.
⚫Do not touch any terminal blocks or IO modules when system is running. Else it may cause the unit to
an electric shock or malfunction.
⚫Keep away from the strange metallic materials not related to the unit and wiring works should be
controlled by the electric expert engineer. Else it may cause the unit to a fire, electric shock or malfunction.
✓If you disobey the instructions, there may be possibility of personal injury, damage to equipment
or explosion. Please follow below Instructions.
⚫Check the rated voltage and terminal array before wiring. Avoid the circumstances over 55℃of
temperature. Avoid placing it directly in the sunlight.
⚫Avoid the place under circumstances over 85% of humidity.
⚫Do not place Modules near by the inflammable material. Else it may cause a fire.
⚫Do not permit any vibration approaching it directly.
⚫Go through module specification carefully, ensure inputs, output connections are made with the
specifications. Use standard cables for wiring.
⚫Use Product under pollution degree 2 environment.
Warning!
Caution!

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HX-RIO3 Series
1.1. Safety Instruction
1.1.1. Symbols
Information about practices or circumstances that can cause an explosion in a
hazardous environment, which may lead to personal injury or death property
damage, or economic loss.
Identifies information that is critical for successful application and understanding of
the Product.
Identifies information about practices or circumstances that can lead to personal
Injury, property damage, or economic loss.
Attentions help you to identity a hazard, avoid a hazard, and recognize the
consequences.
1.1.2. Safety Notes
The modules are equipped with electronic components that may be destroyed by
electrostatic discharge. When handling the modules, ensure that the environment
(persons, workplace and packing) is well grounded. Avoid touching conductive
components, e.g. G-BUS Pin.
1.1.3. Certification
Specification

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HX-RIO3 Series
2. Specification
2.1. Interface
2.1.1. RIO3-MBRL
Pin No.
Signal Description
1
System Power, 24V
2
System Power, 24V
3
F.G
4
Field Power, Ground
5
Field Power, 24V

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HX-RIO3 Series
2.2. Specification
2.2.1. General Specification
General specification
UL System Power
Supply voltage: 24Vdc nominal, Class 2
System Power
Supply voltage: 24Vdc nominal
Supply voltage range: 15~28.8Vdc
Reverse polarity protection
Power Dissipation
20mA typical @ 24Vdc
Current for I/O Module
1.0A @ 5Vdc
Isolation
System power to internal logic: Non-isolation
System power I/O driver: Isolation
UL Field Power
Supply voltage: 24Vdc nominal, Class 2
Field Power
Supply voltage: 24Vdc typical
* Field Power Range is different depending on IO Module series.
Refer to IO Module`s Specification.
Max. Current Field Power Contact
DC 8A Max
Wiring
I/O Cable Max. 2.0㎟(AWG14)
Torque
0.8Nm (7 lb-in)
Weight
77g
Module Size
22mm x 109mm x 70mm
Environmental specification
Operating Temperature
- 20℃~ 60 ℃: 1.0A full load is allowed.
UL Temperature
- 20℃~ 60 ℃
Storage Temperature
- 40℃~ 85 ℃
Relative Humidity
5% ~ 90% non-condensing
Mounting
DIN rail

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HX-RIO3 Series
2.2.2. Interface Specification
Interface Specification RIO3-MBRL (RS-485)
Adapter Type
Slave node (MODBUS Serial RTU/ASCII Server)
Protocol
MODBUS RTU and ASCII
Max. Expansion Module
16 slots
Max. Data Size (Input + Output)
Max. Input 256 bytes / Output 256 bytes
Max Length Bus Line
500m
Max. Nodes
8 nodes
Baud Rate
2400, 4800, 9600, 19200, 38400, 57600, 115200 bps
Interface Connector
RJ-45 socket * 2pcs
Settable Node Address
Via Dip switch
Indicator
4 LEDs
1 Green/Red, Module Status (MOD)
1 Green, Physical Connection (LINK)
1 Green, Exchange Date/Traffic Present (ACTIVE)
1 Green/Red, Expansion I/O Module Status (IOS)
Module Location
Starter module left side of RIO3 Series system
General specification
Shock Operating
IEC 60068-2-27
Vibration Resistance
Based on IEC 60068-2-6
Industrial Emissions
EN 61000-6-4/A11 : 2011
Industrial Immunity
EN 61000-6-2 : 2005
Installation Position
Vertical and horizontal installation is available
Product Certifications
CE, UL, EAC

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HX-RIO3 Series
2.3. LED Indicator
2.3.1 MOD (Module Status LED)
Status
LED
To indicate
Not Powered
OFF
Power is not supplied to the unit.
Device Operational
Green
The unit is operating in normal condition.
Unrecoverable Fault
Red
The device has an unrecoverable fault.
- Memory error or CPU watchdog error.
2.3.2 RXD (Receive Data LED)
Status
LED
To indicate
Not Powered or Not Linked
OFF
Device is idle or may not be powered.
Adapter received correct
message frame
Green
Adapter (Slave) received correct frame which address to the
slave or broadcast. About 20msec flashing
2.3.3 TXD (Transmit Data LED)
Status
LED
To indicate
Not Powered
OFF
Device is idle or may not be powered.
Adapter transmit frame
Flashing Green
Adapter (slave) transmit frame. About 20msec flashing.
2.3.4 IOS LED (Extension Module Status LED)
Status
LED
To indicate
Not Powered
OFF
Device may not be powered.
No Expansion Module
Flashing Red
Adapter has no expansion module
Internal Bus Connection,
Run Exchanging I/O
Green
Exchanging I/O data.
Expansion Configuration
Failed
Red
One or more expansion module occurred in fault state.
- Detected invalid expansion module ID.
- Overflowed Input /Output Size
- Too many expansion module
- Initialization failure
- Communication failure.
- Changed expansion module configuration.
- Mismatch vendor code between adapter and expansion
module.
LED
LED Function / Description
LED Color
MOD
Module Status
Green/Red
RXD
Physical Connection
Green
TXD
Exchange Data/Traffic Present
Green
IOS
Expansion Module Status
Green/Red

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HX-RIO3 Series
3. Dimension
3.1. RIO3-MBRL
(mm)

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HX-RIO3 Series
4. Mechanical Set Up
4.1. Total Expansion
The number of the module assembly that can be connected is 16. So the maximum length is 214mm
Exception.
4.2. Plugging and Removal of the Components
As above figure in order to safeguard the RIO3 module from jamming, it should be fixed onto the DIN rail with
locking level. To do so, fold on the upper of the locking lever.
To pull out the RIO3 module, unfold the locking lever as below figure.
Before work is done on the components, the voltage supply must be turned off.

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HX-RIO3 Series
5. MODBUS Electrical Interface
Slot 16

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HX-RIO3 Series
5.1. G-Bus System
• Network Adapter Module
The Network Adapter Module forms the link between the field bus and the field devices with the Expansion
Modules.
The connection to different field bus systems can be established by each of the corresponding Network
Adapter Module, e.g. for PROFIBUS, CAN open, Ethernet/IP, MODBUS/Serial, MODBUS/TCP etc.
• Expansion Module
The Expansion Modules are supported a variety of input and output field devices.
There are digital and analog input/output modules and special function modules.
• Two types of G-Bus Message
- Service Messaging
- I/O Messaging

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HX-RIO3 Series
5.2 G-Bus Pin Description
Communication between the RIO3 series and the expansion module as well as system / field power supply
of the bus modules is carried out via the internal bus. It is comprised of 6 data pin and 2 field power
ping
Do not touch data and field power pins in order to avoid soiling and damage by ESD
noise.
No.
Name
Description
1
Vcc
System supply voltage (5V dc).
2
GND
System Ground.
3
Token Output
Token output port of Processor module.
4
Serial Output
Transmitter output port of Processor module.
5
Serial Input
Receiver input port of Processor module.
6
Reserved
Reserved for bypass Token.
7
Field GND
Field Ground.
8
Field Vcc
Field supply voltage (24Vdc).

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HX-RIO3 Series
5.3. RIO3-MBRL Electrical Interface
5.3.1. RJ-45 Socket
Shield RJ-45 Socket
5.3.2. MODBUS Dip Switch Setup
Item
Item setup
DIP Switch
#1
#2
#3
#4
#5
#6
#7
#8
#9
#10
Node ID
EEPROM value*
OFF
OFF
OFF
Node ID 1
ON
OFF
OFF
Node ID 7
ON
ON
ON
Baud rate
115200bps
OFF
OFF
OFF
2400 bps
ON
OFF
OFF
4800 bps
OFF
ON
OFF
9600 bps
ON
ON
OFF
19200 bps
OFF
OFF
ON
38400 bps
ON
OFF
ON
57600 bps
OFF
ON
ON
115200 bps
ON
ON
ON
Byte
Format
8bit, No Parity, 1Stop
OFF
OFF
OFF
8bit, Even Parity, 1Stop
ON
OFF
OFF
8bit, Odd Parity, 1Stop
OFF
ON
OFF
8bit, No Parity, 2Stop
ON
ON
OFF
7bit, Even Parity, 1Stop**
ON
OFF
ON
7bit, Odd Parity, 1Stop**
OFF
ON
ON
8bit, No Parity, 1Stop
ON
ON
ON
RTU/ASCI
I Mode
RTU Mode
OFF
ASCII Mode
ON
* Factory default value is 1.
** ASCII Mode is only available
RJ-45
Signal Name
Description
1
RS485 +
Transmit +
2
RS485 −
Transmit −
3
GND
Communication Ground
4
−
5
−
6
−
7
−
8
FG
Frame Ground
Case
Shield

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HX-RIO3 Series
5.3.3. Process Image Map
An expansion module may have 3 types of data as I/O data, configuration parameter and memory register.
The data exchange between Network Adapter and expansion modules is done via an I/O process image data
by RIO3 Series protocol. The following figure shows the data flow of process image between Network Adapter
and expansion modules.
5.3.4. MODBUS Interface Register/Bit Map
• Register Map
Start
Address
Read/Write
Description
Func. Code
0x0000 ~
Read
Process input image registers (Real Input Register)
3,4,23
0x0800 ~
Read/Write
Process output image registers (Real Output Register)
3,16,23
0x1000 *
Read
Adapter Identification special registers.
3,4,23
0x1020 *
Read/Write
Adapter Watchdog, other time special register.
3,4,6,16,23
0x1100 *
Read/Write
Adapter Information special registers.
3,4,6,16,23
0x2000 *
Read/Write
Expansion Slot Information special registers.
3,4,6,16,23
* The special register map must be accessed by read/write of each address (one address).
• Register Map
Start Address
Read/Write
Description
Func. Code
0x0000~
Read
Process input image bits
All input registers area is addressable by bit address.
Size of input image bit is size of input image register * 16.
2
0x1000~
Read/Write
Process output image bits
All output registers area is addressable by bit address.
Size of output image bit is size of output image register *
16.
1,5,15

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HX-RIO3 Series
5.4. Example
5.4.1. Example of Input Process Image (Input Register) Map
Input image data depends on slot position and expansion slot data type. Input process image data is only
ordered by expansion slot position.
Example slot configuration
Address
B15
B14
B13
B12
B11
B10
B9
B8
B7
B6
B5
B4
B3
B2
B1
B0
0x0001
Discrete Input 8 pts (Slot#2)
Discrete Input 8 pts (Slot#1)
0x0002
Analog Input Ch0 high byte (Slot#3)
Analog Input Ch0 low byte (Slot#3)
0x0003
Analog Input Ch1 high byte (Slot#3)
Analog Input Ch1 low byte (Slot#3)
0x0004
Analog Input Ch2 high byte (Slot#3)
Analog Input Ch2 low byte (Slot#3)
0x0005
Analog Input Ch3 high byte (Slot#3)
Analog Input Ch3 low byte (Slot#3)
0x0006
Discrete Input 8 pts (Slot#4)
Discrete Input 8 pts (Slot#4)
0x0007
Discrete Input 8 pts (Slot#6)
Discrete Input 8 pts (Slot#5)
0x0008
Discrete Input 8 pts (Slot#8)
Discrete Input 8 pts (Slot#7)
0x0009
Discrete Input 8 pts (Slot#9)
Discrete Input 8 pts (Slot#8)
Slot
Address
Module Description
#0
MODBUS RS485 Adapter
#1
8-discrete input
#2
8-discrete input
#3
4-analog input
#4
16-discrete input
#5
8-discrete input
#6
8-discrete input
#7
8-discrete input
#8
16-discrete input
#9
8-discrete input

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HX-RIO3 Series
5.4.2. Example of Output Process Image (Output Register) Map
Output image data depends on slot position and expansion slot data type. Output process image data is only
ordered by expansion slot position.
Example slot configuration
Address
B15
B14
B13
B12
B11
B10
B9
B8
B7
B6
B5
B4
B3
B2
B1
B0
0x0800
Discrete Output 8 pts (Slot#2)
Discrete Input 8 pts (Slot#1)
0x0801
Analog Output Ch0 high byte (Slot#3)
Analog Input Ch0 low byte (Slot#3)
0x0802
Analog Output Ch1 high byte (Slot#3)
Analog Input Ch1 low byte (Slot#3)
0x0803
Analog Output Ch2 high byte (Slot#3)
Analog Input Ch2 low byte (Slot#3)
0x0804
Analog Output Ch3 high byte (Slot#3)
Analog Input Ch3 low byte (Slot#3)
0x0805
Empty, Don’t Care
Discrete Out 4 pts
(Slot#5)
Empty, Don’t Care
Discrete Out 4 pts
(Slot#4)
0x0806
Discrete Output low 8 pts (Slot#7)
Discrete Output low 8 pts (Slot#6)
0x0807
Analog Output Ch0 high byte (Slot#8)
Analog Output Ch0 low byte (Slot#8)
0x0808
Analog Output Ch1 high byte (Slot#8)
Analog Output Ch1 low byte (Slot#8)
0x0809
Analog Output Ch2 high byte (Slot#8)
Analog Output Ch2 low byte (Slot#8)
0x080A
Analog Output Ch3 high byte (Slot#8)
Analog Output Ch3 low byte (Slot#8)
0x080B
Discrete Output low 8 pts (Slot#10)
Empty, Don’t Care
Discrete Out 4 pts
(Slot#9)
0x080C
Empty, Don't Care
Discrete Output high 8 pts (Slot#10)
Slot
Address
Module Description
#0
MODBUS RS485 Adapter
#1
8-discrete output
#2
8-discrete output
#3
4-analog output
#4
4-relay output
#5
4-relay output
#6
8-discrete output
#7
8-discrete output
#8
4-analog output
#9
4-relay output
#10
16-discrete output

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HX-RIO3 Series
6. MODBUS TCP/UDP INTERFACE
6.1 MODBUS TCP/ UDP Protocol
The MODBUS messaging service provides a Client/Server communication between devices connected on an
Ethernet
TCP/IP network. All MODBUS/TCP messages are sent via TCP on registered port 502.
Refer to Modbus_Messaging_Implementation_Guide_V1_0a.pdf.
6.1.1. Comparison of MODBUS TCP/UDP and MODBUS/RTU
This header provides some differences compared to the MODBUS RTU application data unit used on serial
line:
• The MODBUS ‘slave address’ field usually used on MODBUS Serial Line is replaced by a single byte ‘Unit
Identifier’ within the MBAP Header. The ‘Unit Identifier’ is used to communicate via devices such as bridges,
routers and gateways that use a single IP address to support multiple independent MODBUS end units.
• All MODBUS requests and responses are designed in such a way that the recipient can verify that a
message is finished. For function codes where the MODBUS PDU has a fixed length, the function code alone
is sufficient. For function codes carrying a variable amount of data in the request or response, the data field
includes a byte count.
• When MODBUS is carried over TCP, additional length information is carried in the MBAP header to allow
the recipient to recognize message boundaries even if the message has been split into multiple packets for
transmission. The existence of explicit and implicit length rules and use of a CRC-32 error check code (on
Ethernet) results in an infinitesimal chance of undetected corruption to a request or response message.
MODBUS TCP/ UDP
MBAP Header
Function
Data
7 chars
1 char
Up to 252 chars
MODBUS RTU
Start
Address
Function
Data
CRC Check
END
≥ 3.5 char
1 char
1 char
Up to 252 chars
2 chars
≥ 3.5 char
Function and data field of MODBUS/TCP are identical to function and data field of MODBUS/RTU.