Moxa Technologies ioPAC 5500 series Instructions for use

ioPAC 5500 Hardware User’s Manual
Edition 2.0, June 2017
www.moxa.com/product
© 2017 Moxa Inc. All rights reserved.

ioPAC 5500 Hardware User’s Manual
The software described in this manual is furnished under a license agreement and may be used only in accordance with
the terms of that agreement.
Copyright Notice
© 2017 Moxa Inc. All rights reserved.
Trademarks
The MOXA logo is a registered trademark of Moxa Inc.
All other trademarks or registered marks in this manual belong to their respective manufacturers.
Disclaimer
Information in this document is subject to change without notice and does not represent a commitment on the part of
Moxa.
Moxa provides this document as is, without warranty of any kind, either expressed or implied, including, but not limited
to, its particular purpose. Moxa reserves the right to make improvements and/or changes to this manual, or to the
products and/or the programs described in this manual, at any time.
Information provided in this manual is intended to be accurate and reliable. However, Moxa assumes no responsibility for
its use, or for any infringements on the rights of third parties that may result from its use.
This product might include unintentional technical or typographical errors. Changes are periodically made to the
information herein to correct such errors, and these changes are incorporated into new editions of the publication.
Technical Support Contact Information
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Table of Contents
1. Introduction...................................................................................................................................... 1-1
Overview...........................................................................................................................................1-2
Package Checklist...............................................................................................................................1-2
Appearance and Dimensions ................................................................................................................1-3
Appearance ................................................................................................................................1-3
Dimensions.................................................................................................................................1-4
Hardware Block Diagrams....................................................................................................................1-4
ioPAC 5500 RTU Controller Block Diagram......................................................................................1-4
Product Hardware Specifications...........................................................................................................1-6
Product Selection Guide ...............................................................................................................1-6
Product Specifications..................................................................................................................1-6
2. Installation ....................................................................................................................................... 2-1
Basic Installation ................................................................................................................................2-2
DIN Rail Installation Procedure......................................................................................................2-2
Configuring the Power.........................................................................................................................2-3
Powering on the ioPAC Controller ..................................................................................................2-3
Grounding the ioPAC....................................................................................................................2-3
Installing a microSD Card ....................................................................................................................2-4
ioPAC 5500 LED Indicators...................................................................................................................2-5
System LEDs ..............................................................................................................................2-6
Communication LEDs...................................................................................................................2-6
Cellular ......................................................................................................................................2-6
User-Defined LEDs: LED1 and LED2...............................................................................................2-6
IEC-61131-3 Compliant LEDs: R/S and ERR....................................................................................2-6
I/O LEDs ....................................................................................................................................2-6
The Toggle Switch ..............................................................................................................................2-7
In IEC-61131-3 Models ................................................................................................................2-7
In C/C++ Models ........................................................................................................................2-7
Toggle Switch: Factory Reset Process....................................................................................................2-7
Pin assignment and I/O wiring guide.....................................................................................................2-8
Pin Assignment ...........................................................................................................................2-8
Digital Input ...............................................................................................................................2-9
Digital Output .............................................................................................................................2-9
Analog Input (Voltage).................................................................................................................2-9
Analog Input (Current).................................................................................................................2-9
Installing a SIM card.........................................................................................................................2-10
Connecting to the Network................................................................................................................. 2-10
Ethernet Communication............................................................................................................2-10
Serial Connectivity............................................................................................................................2-11
Connecting to a Serial Device .....................................................................................................2-11
Serial Console (Debug Port)........................................................................................................2-12
Battery............................................................................................................................................2-13
3. The RTUxpress Utility........................................................................................................................ 3-1
RTUxpress Introduction .......................................................................................................................3-2
Quick Start.................................................................................................................................3-3
User Interface.............................................................................................................................3-6
Device and Service Configuration........................................................................................................3-16
Settings Page ...........................................................................................................................3-16
Log Message Window.................................................................................................................3-16

1
1. Introduction
The following topics are covered in this chapter:

Overview

Package Checklist

Appearance and Dimensions
Appearance
Dimensions

Hardware Block Diagrams
ioPAC 5500 RTU Controller Block Diagram

Product Hardware Specifications
Product Selection Guide
Product Specifications

ioPAC 5500 Hardware Introduction
1-2
Overview
The ioPAC 5500 standalone controllers use an ARM9 based industrial-grade CPU for the main system, with ARM
Cortex™ M4 based CPUs for the I/O channels. The USB bus between the controller CPU and module CPUs
transmits data at up to 200 Mbps, and the dual CPU architecture supports a 2 kHz analog input sampling rate
and millisecond timestamps. The ioPAC 5500 supports C/C++ and IEC 61131-3 programming, rail-level surge
and ESD protection, a -40 to 75°C (-30 to 75°C for HSPA models) operating temperature range, UL/cUL Class
1 Division 2 certification, two 10/100 Mbps Ethernet ports with two MACs (Port Trunking ready), and two 3-in-1
serial ports. With Moxa's Active OPC Server and DA-Center, the ioPAC 5500 series provides a comprehensive
solution for data acquisition and control applications in harsh environments.
Package Checklist
ioPAC 5500
The ioPAC 5500 ships with the following items:
•ioPAC 5500 controller
•Serial console cable (C/C++ models only)
•Documentation and software CD
Optional Accessories (can be purchased separately)
•DK-DC50131: DIN-rail mounting kit, 50 x 131 mm
•CBL-RJ458P-100: 8-pin RJ45 CAT5 Ethernet cable, 100 cm
•CBL-F9DPF1x4-BK-100: Serial console cable
•WK-51-01: Wall-mounting kit, 2 plates with 6 screws
•ANT-WCDMA-AHSM-04-2.5m Black: 3G cellular antenna

ioPAC 5500 Hardware Introduction
1-3
Appearance and Dimensions
Appearance
The following figures depict ioPAC 5500 RTU controller.
Front View
Top View

ioPAC 5500 Hardware Introduction
1-4
Dimensions
Unit: mm (inch)
Hardware Block Diagrams
ioPAC 5500 RTU Controller Block Diagram
CPU Board

ioPAC 5500 Hardware Introduction
1-5
I/O Board
3G Board

ioPAC 5500 Hardware Introduction
1-6
Product Hardware Specifications
Product Selection Guide
Model Name Description
ioPAC 5542-C-T RTU controller, 8AIs, 8 DIs, 8DIOs, C/C++, -40 to 75°C operating
temperature
ioPAC 5542-HSPA-C-T RTU controller with HSPA module, 8AIs, 8 DIs, 8DIOs, C/C++, -30 to 75°C
operating temperature
ioPAC 5542-IEC-T RTU controller, 8AIs, 8 DIs, 8DIOs, IEC 61131-3, -40 to 75°C operating
temperature
ioPAC 5542-HSPA-IEC-T RTU controller with HSPA module, 8AIs, 8 DIs, 8DIOs, IEC 61131-3, -30 to
75°C operating temperature
NOTE
Conformal coating available on request.
Product Specifications
Computer
Main CPU:
32-bit ARM9 192 MHz CPU
I/O CPU:
32-bit ARM Cortex M4 80 MHz CPU
OS:
Linux
Clock:
Real-time clock with battery backup
Memory:
•
SDRAM: 64 MB
• Flash: 32 MB
• SRAM: 256 KB (battery backup lasts for 1 week)
• microSD™ Slot: Up to 32 GB (SD 2.0 compatible)
Note: For units operating in extreme temperatures, industrial grade, wide
-temperature microSD cards are
required.
Cellular (for the ioPAC 5542-HSPA Series)
Network:
• Quad
-band GSM/GPRS/EDGE 850/900/1800/1900 MHz
• Five
-band UMTS/HSPA+ 800/850/AWS/1900/2100 MHz
Internet:
HSPA:
• Up to 5.76 Mbps upload speed
• Up to 14.4 Mbps download speed
UMTS: Up to 384 kbps upload/downloa
d speed
EDGE Class 12: Up to 237 kbps upload/download speed
GPPRS Class 12: Up to 85.6 kbps upload/download speed
SMS:
Point-to-Point Text/PDU mode
SIM Control Voltage:
3/1.8 V
Ethernet Interface
LAN:
2 x 10/100 Mbps, 2 MACs (IPs), RJ45
Protection:
1.5 kV magnetic isolation
Serial Communication
Interface:
• 2 RS
-232/422/485 ports, software selectable (DB9 male)
• 1 RS
-232 debug port (4-pin connector)
Serial Line Protection:
15 kV ESD for all signals

ioPAC 5500 Hardware Introduction
1-7
Serial Communication Parameters
Parity:
None, Even, Odd
Data Bits:
7, 8
Stop Bits:
1, 2
Flow Control:
RTS/CTS, XON/XOFF
Baudrate:
300 bps to 921.6 kbps
Serial Signals
RS
-232: TxD, RxD, DTR, DSR, RTS, CTS, DCD, GND, RI
RS
-422: Tx+, Tx-, Rx+, Rx-, GND
RS
-485-4w: Tx+, Tx-, Rx+, Rx-, GND
RS
-485-2w: Data+, Data-, GND
Inputs and Outputs
Analog Inputs:
8 channels
Digital Inputs:
8 channels
Configurable DIOs:
8 channels
Isolation:
3k VDC or 2k Vrms
Analog Input
Type: Differential Input
Resolution:
16 bits
I/O Mode:
Voltage / Current
Input Range:
0 to 10 VDC, -10 to 10 VDC, 0 to 20 mA, 4 to 20 mA (wire off)
Historical Data Buffering:
60KB per channel, 120 second data buffer at 250 Hz
Accuracy:
±0.1% FSR @ 25°C
±0.3% FSR @
-40 and 75°C
Sampling Rate:
• All
channels: 2000 samples/sec
• Per channel: 250 samples/sec
Input Impedance:
2M ohms (min.)
Built
-in Resistor for Current Input: 120 ohms (min.)
Digital Input
Sensor Type:
Wet Contact (NPN or PNP), Dry Contact
I/O Mode:
DI, Counter or Frequency
Dry
Contact:
• On: short to GND
• Off: open
Wet Contact:
NPN (DI to GND):
• On: 0 to 3 VDC
• Off: 10 to 30 VDC
PNP (DI to GND):
• Off: 0 to 3 VDC
• On: 10 to 30 VDC
Common Type:
4 points per COM
Counter Frequency:
1 kHz
Digital Filtering Time Interval:
Software selectable (by 0.5 ms)
Digital Output
Type:
Sink
I/O Mode:
DO or PWM
Pulse Output Frequency:
1 kHz
Over
-voltage Protection: 45 VDC
Over
-current Protection: 2.6 A (4 channels @ 650 mA)
Over
-temperature Shutdown: 175°C (typical), 150°C (min.)
Current Rating:
200 mA per channel

ioPAC 5500 Hardware Introduction
1-8
Software Characteristics
Automation Languages: C/C++, IEC 61131-3
Protocols:
Modbus TCP/RTU (master/slave), SNMP TCP/IP, UDP, DHCP, BOOTP, SNTP, SMTP
Power Requirements
Power
Input:
• ioPAC 5542
-HSPA series: 305 mA @ 24 VDC
• ioPAC 5542 series: 264 mA @ 24 VDC
Physical Characteristics
Housing:
Aluminum
Dimensions:
90.05 x 135 x 105.4 mm (3.55 x 5.32 x 4.15 in)
Weight:
• ioPAC 5542
-HSPA Series: 1100 g (2.43 lb)
• ioPAC 5542 Series: 1000 g (2.20 lb)
Mounting:
DIN-Rail mounting (standard), wall mounting (optional)
Connector:
Spring-type terminal block
Environmental Limits
Operating Temperature:
• ioPAC 5542 Series:
-40 to 75°C (-40 to 176°F)
• ioPAC 5542
-HSPA Series: -30 to 75°C (-22 to 176°F)
Storage Temperature:
-40 to 85°C (-40 to 185°F)
Ambient Relative Humidity:
5 to 95% (non-condensing)
Shock:
IEC 60068-2-27
Vibration:
IEC 60068-2-6
Altitude:
Up to 2000 m
Note: Please contact Moxa if you require products
guaranteed to function properly at higher altitudes.
Standards and Certifications
Safety:
UL 508
EM
C: EN 55022/24
EMI:
FCC Part 15 Subpart B Class A, CISPR 22
EMS:
IEC 61000
-4-2 ESD: Contact: 4 kV; Air: 8 kV
IEC 61000
-4-3 RS: 80 MHz to 1000 MHz: 3 V/m
IEC 61000
-4-4 EFT: Power: 1 kV; Signal: 0.5 kV
IEC 61000
-4-5 Surge: Power: 2 kV (L-PE), 1 kV (L-L); Signal: 1 kV
IEC 61000
-4-6 CS: 3 V
IEC 61000
-4-8 PFMF: 1 A/m
Radio
:NCC
Rail Traffic:
EN 50121-4
Hazardous Location:
Class 1 Division 2
Note: Please check Moxa’s website for the most up-to-date certification status.
Warranty
Warranty Period:
5 years
Details:
See www.moxa.com/warranty

2
2. Installation
This chapter includes instructions on how to install the ioPAC 5500.
The following topics are covered in this chapter:

Basic Installation
DIN Rail Installation Procedure

Configuring the Power
Powering on the ioPAC Controller
Grounding the ioPAC

Installing a microSD Card

ioPAC 5500 LED Indicators
System LEDs
Communication LEDs
Cellular
User-Defined LEDs: LED1 and LED2
IEC-61131-3 Compliant LEDs: R/S and ERR
I/O LEDs

The Toggle Switch
In IEC-61131-3 Models
In C/C++ Models

Toggle Switch: Factory Reset Process

Pin assignment and I/O wiring guide
Pin Assignment
Digital Input
Digital Output
Analog Input (Voltage)
Analog Input (Current)

Installing a SIM card

Connecting to the Network
Ethernet Communication

Serial Connectivity
Connecting to a Serial Device
Serial Console (Debug Port)

Battery

ioPAC 5500 Hardware Installation
2-2
Basic Installation
DIN Rail Installation Procedure
Installing the ioPAC 5500 on a DIN Rail
The DIN rail attachment plate should already be fixed to the back panel of the ioPAC 5500 when you take it out
of the box. To install the ioPAC 5500 on a DIN Rail, follow below steps.
NOTE
A wall
mount kit can be purchased separately.
STEP 1:
Insert the top of the DIN
rail into the slot just
below the stiff metal spring
.
STEP 2:
The DIN-rail attachment unit will snap into
place as shown
to the right.
Removing the ioPAC 5500 from a DIN Rail
To remove the ioLogik unit from the DIN-rail, simply reverse Steps 1 and 2 above.

ioPAC 5500 Hardware Installation
2-3
Configuring the Power
Powering on the ioPAC Controller
The ioPAC controller can receive power from a 9 to 48 VDC power. Input power is
applied to the positive (
V1+, V2+) and negative (V1-, V2-) terminals on the
connector.
•
When
the input voltage is below the minimum recommended voltage the ioPAC
will turn off.
•
The ioPAC has reverse protection and power input over-voltage protection,
allowing it to resist a maximum voltage of 60 V, and the ioPAC’s power input
over-current fuse protection specification is 5 A at 25°C.
After connecting the Moxa ioPAC controller to the power supply, it will take 30 to 60 seconds for the operating
system to boot up. The green Ready LED will not turn on until the operating system is ready.
ATTENTION
This product is intended to be supplied by a Listed Power Unit with output marked “LPS” and rated for 9
-
48 VDC
(minimum requirements). For railway rolling stock applications, these devices must be supplied by a galvanic
i
solated power supply with design based on the EN 50155 standard.
Grounding the ioPAC
For most applications, it is desirable to ground the system by connecting the system’s power supply common
wire to the chassis or panel ground. The negative (–V) side of the DC power input terminal as well as all I/O
point terminals labeled GND are connected to chassis ground.
NOTE
1.
Use 18 AWG wire for the power ground.
2.
We highly recommend connecting the ground screw to the power terminal block’s ground.

ioPAC 5500 Hardware Installation
2-4
Installing a microSD Card
The ioPAC is equipped with one slot for a microSD card. The card reader slot is located inside the ioPAC device,
so you will need to unscrew and remove the card cover to install your microSD card. When inserting a microSD
card, remember to keep the front edge of the card facing down.
Follow these steps to remove or install a microSD card:
1. Remove the screw holding the card cover in place.
2. (a) Insert a microSD card into the microSD card slot, or
(b) Remove the microSD card from the microSD card slot.
3. Fasten back the screw holding the card cover in place.

ioPAC 5500 Hardware Installation
2-5
ioPAC 5500 LED Indicators
There are 9 LEDs on the ioPAC controller.
Category Label Usage
System
PWR System Power On: Power On
Off: Power Off
RDY System (Kernel)
Ready Green: System Ready Blinking Green: System is booting up
Red: System error, firmware upgrade, or reset
procedure underway
Blinking Red: Factory reset triggered
C/C++ Version LED1, LED2 User-Defined User-Defined
IEC Version
R/S
Run/Stop Mode Green: The CPU is executing PRDK.
OFF: The CPU has stopped / is not executing PRDK.
ERR
Error Red: System / I/O / services error
OFF: No error (auto update if error fixes)
Communication
LAN1, LAN2 Ethernet
Connection Green: 100Mb Amber: 10Mb
Blinking: data transmitting
Off: disconnected
P1, P2 Serial
Connection Green: Transmitting data (Tx) Amber: Receiving data (Rx)
Off: disconnected
Link Cellular
Connection
Green: ISP/IP retrieved
Off: ISP disconnected
Cellular Signal 1 & 2 & 3: ON (RSSI >= 24)
1 & 2: ON (18 <= RSSI < 24)
1: ON Only (12 <= RSSI < 18)
Off: No Signal (RSSI < 12)
I/O DIn, DIOn Digital Input /
Output Indicator Green: Channel ON or counter signal in/pulse signal output (scan rate: 1 second)
Off: Channel OFF or No Counter/Pulse Signal
AIn Analog Input
Indicator Green: Channel Enabled Red: Burn out & wire off when 4-20 mA current mode

ioPAC 5500 Hardware Installation
2-6
System LEDs
PWR (Power LED)
The Power (PWR) LED indicates the status of the system power. When the system is on, this LED will turn green,
and when the system power is off this LED will be off.
RDY (Ready LED)
The Ready (RDY) LED indicates the status of the system’s kernel. When the LED is green the system kernel is
ready. When the LED is green and blinking, the system’s kernel is booting-up. When the Ready (RDY) LED is red,
there is either a system error or the system is being reset to factory defaults. When the Ready LED is red and
blinking, the device’s factory default mode has been triggered.
Communication LEDs
P1 and P2
The ioPAC controller comes with two serial connections. P1 and P2 represent the status of each serial
connection. When the LED is green, the ioPAC is transmitting data (Tx). When the the LED is amber, the ioPAC
is receiving data (Rx). When the LED is blinking randomly, data is either being transmitted or received. For
example, if P1 is blinking and is green, the ioPAC is transmitting data.
When the LED is off, the serial connection is disconnected.
LAN1 and LAN2
The ioPAC controller comes with two Ethernet ports, with the LAN1 and LAN2 LEDs used to represent the status
of the two connections. When the LED is green, data is transmitting at 100 Mbps. When the LED is amber, data
is transmitting at 10 Mbps. When the LED is blinking, data is being transmitted. When the LED is off, there is
no Ethernet connection, or the Ethernet connection has been disconnected.
Cellular
The ioPAC 5542-HSPA RTU controller supports a cellular (HSPA) communications. The Link LED can detect the
communication status and the cellular signal can detect the signal strength of the cellular connection.
User-Defined LEDs: LED1 and LED2
The ioPAC controller allows the user to custom configure these two LEDs (through the software interface).
Refer to the C/C++ Sample Code Programming Guide for ioPAC RTU Controllers for details.
IEC-61131-3 Compliant LEDs: R/S and ERR
The ioPAC controller supports IEC-61131-3-compliant Run/Stop and Error (ERR) LEDs for ISaGRAF-specific
notifications. These LEDs are not user configurable.
I/O LEDs
The ioPAC 5542 RTU controller has I/O LED indicators that directly display the status of I/Os on the front panel
of the ioPAC 5542 RTU controller.

ioPAC 5500 Hardware Installation
2-7
The Toggle Switch
The toggle switch functions differently depending on the programming language set your ioPAC model is
configured for.
In IEC-61131-3 Models
For IEC-61131-3 models, the toggle switch is a simple run/stop switch for IEC
programs. Users can enable or disable it through RTUxpress. The default
setting is disabled.
In C/C++ Models
On models that use the C language set, the toggle switch is programmable,
giving integrators and end-users a switch that can trigger one of two
operation modes (refer to the C/C++ Sample Code Programming Guide
for ioPAC RTU Controllers for details).
Toggle Switch: Factory Reset Process
Use the following procedure to reset the ioPAC to the factory defaults. Note that when you reset the ioPAC, all
of your tag definitions, software programs, and files will be deleted, and the service and runtime engine will be
restarted.
1. When the system is booting up and the RDY LED is blinking GREEN, hold the toggle switch in the “reset”
position.
2. Continue to hold toggle switch until the “RDY” LED turns a solid RED, and then release the toggle switch. It
will take around 90 seconds to complete the factory reset process.
3. When the “RDY” LED starts blinking GREEN (indicating that the kernel is rebooting), the factory mode is
completed.
NOTE
Do NOT power off, operate, or connect any devices when the “RDY” LED is a solid RED.
The factory reset
function is only activated when the system is booting up.

ioPAC 5500 Hardware Installation
2-8
Pin assignment and I/O wiring guide
The following is the ioPAC 5542 RTU controller’s pin assignment and I/O wiring guide.
Pin Assignment
Pin Name Description Pin Name Description
1 COM0 COM of DI0, DI2, DI4,
and DI6 2 COM1 COM of DI1, DI3, DI5, and DI7
3 DI0 Digital Input Channel 0 4 DI1 Digital Input Channel 1
5 DI2 Digital Input Channel 2 6 DI3 Digital Input Channel 3
7 DI4 Digital Input Channel 4 8 DI5 Digital Input Channel 5
9 DI6 Digital Input Channel 6 10 DI7 Digital Input Channel 7
11 GND Ground 12 GND Ground
13 COM2 COM of DIO0, DIO2,
DIO4, and DIO6 14 COM3 COM of DIO1, DIO3, DIO5, and DIO7
15 DIO0 Digital Input/Output
Channel 0 16 DIO1 Digital Input/Output Channel 1
17 DIO2 Digital Input/Output
Channel 2 18 DIO3 Digital Input/Output Channel 3
19 DIO4 Digital Input/Output
Channel 4 20 DIO5 Digital Input/Output Channel 5
21 DIO6 Digital Input/Output
Channel 6 22 DIO7 Digital Input/Output Channel 7
23 GND Ground 24 GND Ground
25 AI0+ Analog Input Channel 0 +
26 AI1+ Analog Input Channel 1 +
27 AI0- Analog Input Channel 0 - 28 AI1- Analog Input Channel 1 -
29 AI2+ Analog Input Channel 2 +
30 AI3+ Analog Input Channel 3 +
31 AI2- Analog Input Channel 2 - 32 AI3- Analog Input Channel 3 -
33 AI4+ Analog Input Channel 4 +
34 AI5+ Analog Input Channel 5 +
35 AI4- Analog Input Channel 4 - 36 AI5- Analog Input Channel 5 -
37 AI6+ Analog Input Channel 6 +
38 AI7+ Analog Input Channel 7 +
39 AI6- Analog Input Channel 6 - 40 AI7- Analog Input Channel 7 -