Hydronix EA01 User manual

Hydronix Ethernet Adapter User Guide HD0333 Rev 2.1.0 11
Kit Contents
A – Ethernet Adapter – EA01
B – Ethernet Power Adapter – EPA01
C – Ethernet Power Injector – EPI01
D – IEC Mains Cable
E – Ethernet Patch Cables x 3
Order Options:
Ethernet Adapter Kit Part Number: EAK01
Comprises: Ethernet Adapter, Ethernet Patch Cable (0.5m), User Guide, CD
with Hydro-Com software and User Guide
Use: Use with external 24V power supply
Ethernet Power Adapter Kit: Part Number: EPK01
Comprises: All the above plus Ethernet Power Adapter, Power Injector, IEC
mains cable and 2 additional Ethernet Patch Cables
Use: Provides power and Ethernet connection over standard CAT5e
cable
A
B
C
D
E

Hydronix Ethernet Adapter User Guide HD0333 Rev 2.1.0 13
Chapter 1 Introduction
The Hydronix Ethernet Adapter provides a simple method of network enabling Hydronix products. The
Adapter is a small DIN-rail mounted unit that converts packets received over an Ethernet (TCP/IP)
network to RS485 or RS232. This enables a host PC elsewhere on the network to communicate with
sensors using Hydronix Hydro-Com software. Remote configuration and control of a Hydro-Control VI
unit is also possible.
An option of using Power over Ethernet is available via a second small DIN-rail module to eliminate
the need for a local 24V supply for the sensors.
Figure 1: Ethernet Adapter Kit Connections

Hydronix Ethernet Adapter User Guide HD0333 Rev 2.1.0 15
Chapter 2 Connecting with Sensors
1 Installation
Depending on the installation option chosen, the system should be set up as shown in the
diagrams below. Terminal identification for each module is shown later in this chapter. In order to
maintain compliance with the relevant product directives, this equipment should only be installed
and used with the approved components supplied by Hydronix. Unauthorised modifications to
the units could void the units compliance and invalidate the users right to use the equipment.
1.1 Ethernet Adapter Only (EA01)
The most basic setup uses only the Ethernet Adapter and is arranged as shown below:
Cable To Sensor
Black
RS/485 A
RS/485 B
0v DC
24v DC
Colour
White
Black
Red
MILSPEC
F
G
B
A
EA01
Ethernet
Adapter
1
24v DC
Power Supply
0v 24v
10/100baseT
CAT5e
Ethernet
to network
Figure 2: Connections for Ethernet Adapter only
1.1.1 Location of the Ethernet Adapter (EA01)
The Ethernet Adapter should be mounted in the wiring junction box as close to the sensors
as possible, and protected from water and excessive dust. The Ethernet Adapter (EA01)
should be installed in such a manner as to prevent electro-static discharge to the Ethernet
“IN” port. Such a discharge may cause the unit to lock up and require a power “OFF –
ON” cycle to restore performance.
Connect the Ethernet drop cable from the network connection to the Ethernet port of the
Adapter. Connect a 24V dc supply to the 24V+ and 0V input terminals of the Ethernet
Adapter, ensuring that the power supply and wire is of a sufficient power rating to carry the
power for the number of sensors connected
Connect the RS485 sensor cable to the Ethernet Adapter outputs, taking care to note the
recommendations in the RS485 Wiring Recommendations later in the chapter.

Connecting with Sensors Chapter 2
16 Hydronix Ethernet Adapter User Guide HD0333 Rev 2.1.0
1.2 Power over Ethernet (EPK01)
To eliminate the need for a local 24V supply for the adapter and sensors, the optional Power
over Ethernet kit can be used. The arrangement is as shown below:
Junction box close to sensorsControl Room Cabinet
Cable To Sensor
Black
RS/485 A
RS/485 B
0v DC
24v DC
Colour
White
Black
Red
MILSPEC
F
G
B
A
EPA01
Ethernet
Power
Adapter
1
EA01
Ethernet
Adapter
1
10/100baseT
CAT5e
linking
EPA01 and
EA01
EPI01
Ethernet
Power
Injector
OUT IN
IEC Mains
Cable
100-240v
50-60Hz
10/100baseT
CAT5e
Ethernet
to EPI01
10/100baseT
CAT5e
Ethernet
to EPA01
10/100baseT
CAT5e
Ethernet
to Network
Figure 3: Connections for Ethernet Adapter and Power Adapter
1.2.1 Location of the Ethernet Power Adapter (EPA01)
The Power Adapter Module (EPA01) should be mounted in the wiring junction box close to
the sensors and beside the Ethernet Adapter, protected from water and excessive dust.
Connect the Ethernet drop cable from the router to the IN port of the Power Adapter. This
cable carries both the power and the Ethernet communications signals. Connect a short
Ethernet cable from the OUT port of the Power Adapter to the Ethernet port on the
Adapter. This cable carries only the Ethernet communications. Connect short insulated
wires from the 24V+ and 0V outputs of the Power Adapter to the 24V+ and 0V inputs of
the Ethernet Adapter, ensuring that the wire is of sufficient power rating to carry the power
for the number of sensors connected.
Connect the RS485 sensor cable to the Ethernet Adapter outputs, taking care to note the
recommendations in the RS485 Wiring Recommendations later in this chapter.
Sufficient ventilation and cooling should be employed to keep the air temperature around
the unit to a suitable level for the number of sensors being powered. The diagram below
shows the number of sensors that can be used at different air temperatures for each
sensor type.

Chapter 2 Connecting with Sensors
Hydronix Ethernet Adapter User Guide HD0333 Rev 2.1.0 17
Figure 4: Maximum number of sensor connections dependent upon ambient temperature
NOTE: Operation above these limits may cause premature failure of the unit.
1.2.2 Location of the Power Injector Module (EPI01)
The Power Injector Module (EPI01) should ideally be located in the computer room or
network cabinet close to the router. Identify which drop cable runs to the sensor location,
and using a short patch cable insert the Power Injector into that cable, connecting the port
labelled IN to the router output and the port labelled OUT to the drop cable. Connect a
240V or 110V mains supply to the Power Injector.
Note: The Power Injector Module can supply sufficient power for up to three Hydronix
sensors (or 4 Hydro-Probe II sensors). If more sensors are to be connected to the network,
then a separate power supply local to the sensors should be used instead of the Power
over Ethernet solution.
2 Connections
2.1 Wiring Connections
2.1.1 Ethernet Adapter sensor connections:
Ethernet Adapter Terminal Signal
Description MIL Spec pin
number on sensor
Wire Colour in
standard Hydronix
0090A cable
1
24V + input
2
0V input
3
24V + to sensor
A
Red
4
0V to sensor
B
Black
5
RS485 B
G
Black
6
RS485 A
F
White
The white and black are from one twisted pair and the red and black from another.
HydroProbe II
0
1
2
3
4
5
010 20 30 40 50 60 70 80
Maximum Air Temperature
Number of Sensors

Connecting with Sensors Chapter 2
18 Hydronix Ethernet Adapter User Guide HD0333 Rev 2.1.0
2.1.2 Ethernet Power Adapter connections:
Ethernet Power Adapter Terminal
Signal Description
1
0V output
5
24V + output
2.2 RS-485 Wiring Recommendations
The performance and reliability of a RS485 network can depend significantly on the quality
and design of the wiring used. It is recommended to use 24AWG twisted pairs with a
characteristic impedance (Zo) of 100R – 120R. Ideally, sensors on a RS485 network should
be connected in a daisy chain arrangement, as shown here:
This arrangement uses just one of the sets of sensor outputs on the Ethernet Adapter. In
practice, this arrangement is hard to achieve, so sensors may be wired using very short stubs:
Although the Ethernet Adapter has multiple sets of sensor outputs, wiring in a star
configuration with each sensor wired to an output set should be avoided if at all possible.
3 Indicator Lights
The Ethernet Power Adapter unit (EPA01) has a single red indicator light on the top, which
indicates that it is supplying power. It must be connected to an Ethernet cable with an 802.11af
compliant Power Injector supplying it.
The Ethernet Adapter (EA01) has three indicator lights on the top. The red indicator illuminates
when a suitable 24V supply is connected. The transmit indicator light blinks when data is
received by the Adapter and is being sent to the sensors. The receive indicator light blinks when
data is received from the sensors and is being sent over the Ethernet to the host system.
Additionally, the green indicator light above the network connector indicates that a network
connection has been established, and the yellow indicator blinks when network data is sent or
received

Chapter 2 Connecting with Sensors
Hydronix Ethernet Adapter User Guide HD0333 Rev 2.1.0 19
4 Programming
An installation using the Ethernet Adapter packs the messages sent from a Host to the Sensor
into an Ethernet data packet, which is then unpacked by the Ethernet Adapter and converted into
RS485 voltage levels. If a custom application is being written to communicate with Hydronix
sensors over the Ethernet, then the Hydro-Link communications protocol should be implemented
and the resulting message string sent over the network to the Ethernet Adapter (instead of a
serial port). In Visual Basic (VB6) this is done using a WinSock control and in Visual Studio .NET
this can either be done using a Sockets control or a TCP Client control. A connection should be
made from the Winsock or TCP Client control to port 10001 on the Adapter.
Further information on these controls can be found in the programming system documentation.
Although Hydronix is able to provide guidance they may be unable to give detailed technical
support for developing custom software applications.
Hydronix are currently developing a Class Library for .NET to implement all of the
communications functionality including support for the Ethernet Adapter, which will be available
upon request. For details of this and more information on the Hydro-Link Communications
Protocol please contact Hydronix Technical Support ([e-mail])

Hydronix Ethernet Adapter User Guide HD0333 Rev 2.1.0 21
Chapter 3 Connecting with Hydro-Control VI
1 Introduction
The serial port of a Hydro-Control VI unit may be connected to the RS232 port of an Ethernet
Adapter to allow remote access to recipe configuration and mix logs.
This cannot be done while an Adapter is communicating with sensors, as a different
communications protocol is used. Installation will be similar to one of the options described in the
previous chapter, except that the RS232 Tx, Rx and GND signals will be connected to the Hydro-
Control VI unit.
2 Installation
Depending on the installation option chosen, the system should be set up as shown in the
diagrams below. Terminal identification for each module is shown later in this chapter.
In order to maintain compliance with the relevant product directives, this equipment should only
be installed and used with the approved components supplied by Hydronix. Unauthorized
modifications to these units could void the units compliance and invalidate the users right to use
the equipment.
2.1 Ethernet Adapter Only
The most basic setup uses only the Ethernet adapter and is arranged as shown below:
10/100baseT
CAT5e
Ethernet to Network
Ethernet
Adapter
24V
Receive
Transmit
Model: EA01
Connections to Hydro-Control VI
Description Connector Pin
RS232 Gnd 28
RS232 Rx 26
RS232 Tx 27
0v DC 34
24v DC 32
24v DC
Power Supply
0v 24v
Figure 5: Connecting the Ethernet Adapter to Hydro-Control VI

Connecting with Hydro-Control VI Chapter 3
22 Hydronix Ethernet Adapter User Guide HD0333 Rev 2.1.0
2.1.1 Location of the Ethernet Adapter (EA01)
The Ethernet Adapter should be mounted in the wiring junction box as close to the Hydro-
Control VI as possible, and protected from water and excessive dust. Connect the
Ethernet drop cable from the network connection to the Ethernet port of the Adapter.
Connect a 24V dc supply to the 24V+ and 0V input terminals of the Ethernet Adapter,
ensuring that the power supply and wire is of a sufficient power rating to carry the power
for the number of sensors connected.
2.2 Power over Ethernet (EPK01)
A single Hydro-Control VI unit (with attached Hydro-Mix sensor) can be powered using the
Power over Ethernet kit. Connect one of the Sensor 24V and 0V connections to the Hydro-
Control VI power input pins. The arrangement is as shown below:
10/100baseT
CAT5e
Linking EPA01 and EA01
Connections to Hydro-Control VI
Description Connector Pin
RS232 Gnd 28
RS232 Rx 26
RS232 Tx 27
0v DC 34
Ethernet
Adapter
Model: EA01
24V
Receive
Transmit
Ethernet
Power
Adapter
Model: EPA01
IN
24V
OUT
Junction box close to Hydro-Control VI
Control Room Cabinet
10/100baseT
CAT5e
Ethernet
to EPI01
10/100baseT
CAT5e
Ethernet
to Network
Switch
EPI01
Ethernet
Power
Injector
OUT IN
10/100baseT
CAT5e
Ethernet
to EPA01
IEC Mains
Cable
100-240v AC
50-60Hz
24v DC 32
Figure 6: Connecting the Ethernet Adapter to Hydro-Control VI
with Power Over Ethernet Option
2.2.1 Location of the Power Adapter (EPA01)
The Power Adapter Module (EPA01) should be mounted in the wiring junction box with the
Hydro-Control and beside the Ethernet Adapter, protected from water and excessive dust.
Connect the Ethernet drop cable from the router to the IN port of the Power Adapter. This
cable carries both the power and the Ethernet communications signals. Connect a short
Ethernet cable from the OUT port of the Power Adapter to the Ethernet port on the
Adapter. This cable carries only the Ethernet communications. Connect short insulated
wires from the 24V+ and 0V outputs of the Power Adapter to the 24V+ and 0V inputs of
the Ethernet Adapter, ensuring that the wire is of sufficient power rating to carry the power
for the Hydro-Control VI and it’s sensor.
Connect RS232 cables between the Ethernet Adapter and the Hydro-Control VI.

Chapter 3 Connecting with Hydro-Control VI
Hydronix Ethernet Adapter User Guide HD0333 Rev 2.1.0 23
2.2.2 Location of the Power Injector Module (EPI01)
The Power Injector Module (EPI01) should ideally be located in the computer room or
network cabinet close to the router. Identify which drop cable runs to the Hydro-Control’s
location, and using a short patch cable insert the Power Injector into that cable, connecting
the port labelled IN to the router output and the port labelled OUT to the drop cable.
Connect a 240V or 110V mains supply to the Power Injector.
Note: The Power Injector Module can supply sufficient power for a Hydro-Control
VI and a sensor attached to it.
2.2.3 Ethernet Adapter Hydro-Control VI connections
Ethernet
Adapter
Terminal
Signal
Description
Signal Function
Hydro-Control
VI Pin
3
24V + to sensor
24v to Hydro-Control VI
31
4
0v to sensor
0v to Hydro-Control VI
33
8
RS232 RTS
RS232 Ready To Send
Not used
9
RS232 Tx
Data from Ethernet Adapter to
Hydro-Control VI
26
10
RS232 Rx
Data from Hydro-Control VI to
Ethernet Adapter
27
11
RS232 CTS
RS232 Clear To Send
Not used
12
RS232 GND
Ground connection
28
3 Connecting with Hydro-Control VI
To communicate with a Hydro-Control VI unit, start a terminal emulation program such as
HyperTerminal and set the connection properties as shown, substituting the correct IP Address.
Note specifically that the Port number should be set to 10001.
The same “ * “ commands can be used as would normally be used over
a serial link, and the responses will provide the same information. Refer
to the Hydro-Control VI Users Guide for more details of the commands
available

Hydronix Ethernet Adapter User Guide HD0333 Rev 2.1.0 25
Chapter 4 Configuring the Ethernet Adapter
1 Ethernet Adapter defaults
By default, the Ethernet Adapter will use an automatically generated IP Address, which will be
allocated by the network DHCP server. As this may change after a few days or weeks, it is
recommended that a fixed IP Address is used for the Ethernet Adapter. The allocated address
should be on the same subnet as the address allocated by DHCP, but outside the range of
DHCP addresses. Contact the Network Administrator to find a suitable address.
2 Finding an Ethernet Adapter automatically
Communication with Hydronix sensors is carried out with the Hydro-Com Utility. To start go to the
Communications->TCP/IP menu in Hydro-Com and select “Search for Ethernet Adapters”.
The program will display a search window and query the network for any sensors attached.
The adapter will be added to the list, select it to connect.

Configuring the Ethernet Adapter Chapter 4
26 Hydronix Ethernet Adapter User Guide HD0333 Rev 2.1.0
3 Adding an Ethernet Adapter manually
In order to manually enter an Ethernet Adapter’s IP Address select Communications->TCP/IP-
>Add Ethernet Adapter.
In the dialog that is shown, enter the IP Address and Port Number (usually 10001) of the
Ethernet Adapter
The adapter will be added to the list, select it to connect.

Chapter 4 Configuring the Ethernet Adapter
Hydronix Ethernet Adapter User Guide HD0333 Rev 2.1.0 27
4 Changing the Ethernet Adapter IP Address
Once Hydro-com is connected to an Ethernet Adapter, go to the “Diagnostics” tab, login then
click on the button “Settings” in the Ethernet Adapter frame
To fix the IP Address, click on “Use fixed IP Address” and enter the IP
Address in the box provided. It is recommended to leave the Port Number
and Gateway set to the defaults. Click “Set” and then after the progress bar
has completed and the new information has been written, click “Exit” to close
the dialog and go back to the main screen.
When a fixed IP Address has been assigned, it is recommended to write the
address on the front of the Ethernet Adapter in the space provided.
5 Remote (Internet) Connection
Sensors connected to an Ethernet Adapter can also be accessed remotely over the Internet. In
order to do this, it is necessary to open up a port in the Firewall of the network on which the
Ethernet Adapter is installed. Contact the Network Administrator for details of doing this. When
opening the Port, all incoming traffic to that port should be directed to the IP Address of the
Ethernet Adapter and port 10001. Make a note of the network’s IP Address on the Internet and
the number of the port opened up. The table below shows the settings used in this example:
Company Network Settings
Ethernet Adapter Settings
IP Address
Opened Port
IP Address
Port Number
123.456.78.901
7011
192.168.10.61
10001

Configuring the Ethernet Adapter Chapter 4
28 Hydronix Ethernet Adapter User Guide HD0333 Rev 2.1.0
The port 7011 on the Firewall is opened up and all traffic to this port is forwarded to
192.168.10.61 port 10001.
If the Firewall does not allow a completely flexible configuration of port forwarding then either
open up port 10001 on the Firewall and leave the Ethernet Adapter port set as 10001, or
alternatively alter the port of the Ethernet Adapter to be the same
as the port opened in the Firewall. This is done by entering the new
value in the Port Number box when setting the fixed IP Address:
Certain port numbers are reserved for internal use by the Ethernet
Adapter and should not be used:
Port Number
Function
1 – 1024
Commonly used Internet Ports
9999
Ethernet Adapter Reserved
functionality
14000 – 14009
30704
30718
Hydro-Com prevents you from setting these port numbers.
Install Hydro-Com on the remote machine. As before, select Communications->TCP/IP->Add
Ethernet Adapter. In the Add Ethernet Adapter window, enter the IP Address of the Firewall and
the Port opened.

Hydronix Ethernet Adapter User Guide HD0333 Rev 2.1.0 29
Chapter 5 Technical Specifications
1 EA01 Ethernet Adapter
Dimensions: 70mm (w) x 86mm (h) x 57mm (d)
Environment: Operating Temperature 0-70°C
Modules should be used indoors in dry environments only. The enclosures are rated to IP31.
Interfaces: Ethernet IN: Standard 10/100baseT Ethernet RJ45 socket
RS485: Can connect to a maximum of 16 Hydronix Sensors
RS232: Standard RS232 interface
Weight: 160g
2 EPA01 Ethernet Power Adapter
Dimensions: 35mm (w) x 86mm (h) x 57mm (d)
Environment: Operating Temperature:0-70°C
Modules should be used indoors in dry environments only. The enclosures are rated to IP31.
Power Output: 24V, 630mA – see notes in Chapter 2 on number of sensors that can be
powered.
Interfaces:Ethernet IN: Standard 802.11af 10/100baseT Power over Ethernet RJ45 socket
Ethernet OUT: Standard 10/100baseT Ethernet RJ45 socket
Weight: 123g
3 EPI01 Ethernet Power Injector
Dimensions: 65mm (w) x 140mm (h) x 36mm (d)
Environment: Operating Temperature: 0-40°C
Modules should be used indoors in dry environments only.
Interfaces:Mains In: IEC320 inlet 3 pin
Ethernet IN: Standard 10/100baseT Ethernet RJ45 socket
Ethernet OUT: Standard 802.11af 10/100baseT Power over Ethernet RJ45 socket
Weight: 246g
NOTE: Allow space for cables to be fitted on all units

Technical Specifications Chapter 5
30 Hydronix Ethernet Adapter User Guide HD0333 Rev 2.1.0
4 Terminal Identification
The Ethernet Adapter terminals are wired as follows:
EA01
Ethernet
Adapter
112
13 24
IN
Figure 7: EA01 Terminal Identification
Ethernet
Adapter
Terminal
Signal
Description
Notes
IN
CAT5e Network cable
1
24V + input
2
0V input
3
24V + to sensor
4
0V to sensor
5
RS485 B
6
RS485 A
7
No connection
8
RS232 RTS
9
RS232 Tx
10
RS232 Rx
11
RS232 CTS
12
RS232 GND
13
24V + to sensor
It is not recommended to wire RS485
using a star topology
Please refer to chapter 2 on RS485
wiring recommendations
14
0V to sensor
15
RS485 B
16
RS485 A
17
24V + to sensor

Chapter 5 Technical Specifications
Hydronix Ethernet Adapter User Guide HD0333 Rev 2.1.0 31
18
0V to sensor
19
RS485 B
20
RS485 A
21
24V + to sensor
22
0V to sensor
23
RS485 B
24
RS485 A
The Ethernet Power Adapter EPA01 terminals are wired as follows. Particular care must be
taken to identify the top and bottom of the unit, as both sides look similar.
EPA01
Ethernet
Power
Adapter
610
15
IN
OUT
Figure 8: EPA01 Terminal Identification
Ethernet Power Adapter
Terminal
Signal
Description
IN
CAT5e Network cable from EPI01
OUT
CAT5e Network cable to EA01
1
0V output
2
0V output
3
No connection
4
24V + output
5
24V + output
6
0V output
7
0V output

Technical Specifications Chapter 5
32 Hydronix Ethernet Adapter User Guide HD0333 Rev 2.1.0
8
No connection
9
24V + output
10
24V + output

Hydronix Ethernet Adapter User Guide HD0333 Rev 2.1.0 33
Chapter 6 Fault Finding
1 Ethernet Adapter EA01
Symptom: 24V light not on
Possible Explanation
Check
Required Result
Action required on
failure
24V not connected
DC power on terminals
1 and 2
+24v DC
Locate fault in power
supply
Symptom: Not found on network using the Hydro-Com Search function
Possible Explanation
Check
Required Result
Action required on
failure
Not connected to
network
Ethernet link
Ethernet link light lit
Locate fault in network
cabling
No DHCP address
DHCP server
IP address assigned
Unplug and replug the
network cable
2 Ethernet Power Adapter EPA01
Symptom: 24V light not on
Possible Explanation
Check
Required Result
Action required on
failure
Ethernet Power Injector
not connected
Ethernet Power Injector
EPI01 as above
24V light on
Ethernet cables plugged
in wrong way round
Try swapping the
cables – the Power
Injector should go to IN
and the OUT should go
to the Ethernet Adapter
24V light on
Symptom: Computer does not communicate with the Ethernet Adapter
Possible Explanation
Check
Required Result
Action required on
failure
Not properly registered
on network
Search for the Ethernet
adapter using the
Hydro-Com ‘Search’
function.
If that fails then try
pinging the IP address
of the Ethernet Adapter
Ethernet Adapter found
Ping response
Investigate network –
try power cycling EA01
Check IP Address
Invalid IP address
If the subnet mask is
255.255.255.0 then if
Connection from
Hydro-Com to Ethernet
Contact local network
administrator or

Fault Finding Chapter 6
34 Hydronix Ethernet Adapter User Guide HD0333 Rev 2.1.0
the adapter’s IP
address x.y.z.a then the
PC’s must be x.y.z.b (b
<> a) try changing the
PC’s to match and try
again
Adapter – then the IP
Address can be
changed
Hydronix Technical
Support
Symptom: Computer does not communicate with the sensor
Possible Explanation
Check
Required Result
Action required on
failure
Not wired correctly to
sensor
Wiring connections of
EA01
Transmit and receive
lights blink
Check sensor
connections, try a
different sensor
3 Ethernet Power Injector EPI01
Symptom: ON light not illuminated
Possible Explanation
Check
Required Result
Action required on
failure
Ethernet Power Injector
not plugged in
Power supply to
Ethernet Power Injector
ON light illuminated
Try a different EPI01
Symptom: CONNECT light not illuminated
Possible Explanation
Check
Required Result
Action required on
failure
Ethernet cable to
Ethernet Power Adapter
faulty or not connected
Cable between EPI01
and EPA01
CONNECT light
illuminated
Replace cable or try a
different EPA01