Moxa Technologies ioPAC 8020 User manual

ioPAC 8020 Modular RTU Controller
User’s Manual
First Edition, September 2010
www.moxa.com/product
© 2010 Moxa Inc. All rights reserved.
Reproduction without permission is prohibited.

ioPAC 8020 Modular RTU Controller
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
Copyright ©2010 Moxa Inc.
All rights reserved.
Reproduction without permission is prohibited.
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
www.moxa.com/support
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Toll-free: 1-888-669-2872
Tel: [phone]
Fax: [phone]
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Toll-free: 800-820-5036
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Table of Contents
1. Introduction ...................................................................................................................................... 1-1
ioPAC 8020 Rugged Remote I/O Overview .............................................................................................1-2
Product Features ................................................................................................................................1-2
Package Checklist ...............................................................................................................................1-3
Available Products: .............................................................................................................................1-4
Product Specifications .........................................................................................................................1-4
Physical Dimensions............................................................................................................................1-6
Hardware Reference............................................................................................................................1-7
2. Initial Setup ...................................................................................................................................... 2-1
System Architecture............................................................................................................................2-2
Installing the ioPAC on a DIN-Rail .........................................................................................................2-2
Removing the ioPAC from the DIN-Rail...........................................................................................2-3
Grounding the ioPAC System ........................................................................................................2-3
Inserting/Removing I/O Modules from the ioPAC .............................................................................2-3
Connecting the Power System.......................................................................................................2-4
Connecting to the Network ...........................................................................................................2-4
3. Utilities ............................................................................................................................................. 3-1
Introduction to Modular_ioAdmin ..........................................................................................................3-2
Features of ioAdmin.....................................................................................................................3-2
Modular ioAdmin Main Screen ..............................................................................................................3-6
Main Screen Overview..................................................................................................................3-6
Functions on the Menu Bar ...........................................................................................................3-6
Watchdog Tab (Administrator) .................................................................................................... 3-14
Click&Go Logic Tab (Administrator) ............................................................................................. 3-15
SNMP Tab (Administrator) .......................................................................................................... 3-15
Using TFTP to Import/Export Configuration .......................................................................................... 3-15
4. Using the Built-in Web Console ......................................................................................................... 4-1
Overview for ioPAC 8020 .....................................................................................................................4-2
Entering the Web Console....................................................................................................................4-2
Overview ...........................................................................................................................................4-3
Basic Settings .............................................................................................................................4-3
Network Settings.........................................................................................................................4-3
5. Click&Go Introduction ....................................................................................................................... 5-1
Overview ...........................................................................................................................................5-2
Features ............................................................................................................................................5-3
Click&Go Logic Basics..........................................................................................................................5-3
Working with Rules .............................................................................................................................5-4
Developing Your Logic Rules ................................................................................................................5-4
Define Global Variables........................................................................................................................5-5
Internal Register Settings.............................................................................................................5-5
Timer Settings ............................................................................................................................5-6
SNMP Trap Server .......................................................................................................................5-6
E-Mail Server ..............................................................................................................................5-7
Active Message Server .................................................................................................................5-8
IF/THEN/ELSE Statement ....................................................................................................................5-8
IF Conditions ..............................................................................................................................5-9
THEN/ELSE Actions.................................................................................................................... 5-10
Working with Click&Go Rulesets ......................................................................................................... 5-12
Activating the Ruleset ................................................................................................................ 5-12
6. Hot-swappable I/O Function............................................................................................................. 6-1
Hot-swappable I/O Function.................................................................................................................6-2
Handling unmatched module combination event .....................................................................................6-2
Turn Off the Module Order Check: ........................................................................................................6-3
A. Modules Specifications and Wiring .................................................................................................... A-1
B. Using Modbus/TCP ............................................................................................................................ B-1
C. Modbus/TCP Address Mappings ........................................................................................................ C-1
I/O Image Map ...................................................................................................................................C-1
Module Configuration Map (Holding register map) ...................................................................................C-2
System Configuration Map (Input register map) .....................................................................................C-3
Modbus Table.....................................................................................................................................C-3
System Configuration Map............................................................................................................C-3
D. Used Network Port Numbers ............................................................................................................. D-1
E. SNMP MIB file ................................................................................................................................... E-1

F. Factory Default Settings.................................................................................................................... F-1

1
1. Introduction
The ioPAC 8020 modular RTU controller is a rugged, modularized, and flexible I/O combination system. It is
designed for harsh environments, such as rolling stock, mining facilities, etc. The hot swappable I/O modules
can connect to various sensors and on/off switches for automation applications and the CPU module provides
local intelligence that can communicate over Ethernet and IP-based networks.
The following topics are covered in this chapter:

ioPAC 8020 Modular RTU Controller

Product Features

Package Checklist

Available Products:

Product Specifications

Physical Dimensions

Hardware Reference

ioPAC 8020 Rugged Remote I/O Introduction
1-2
ioPAC 8020 Modular RTU Controller
The ioPAC modular RTU controller is an automation system which combines one CPU module with hot
swappable I/O modules. This modularity gives the ioPAC 8020 enormous flexibility. The slice type I/O modules
that can connect to any combination of sensors and on/off devices, and can transfer the captured data or
device status to a host computer via an Ethernet or IP-based networks. The system is designed for applications
in harsh environments. It has wider operation temperature of -40 to 70°C and vibration resistance. The rugged
aluminum chassis can resist UV rays to prevent wear and tear.
The ioPAC modular RTU controller consists of two major components: the CPU Module, which includes empty
I/O slots, and the I/O modules themselves. The CPU module provides the capability for daisy-chain
communications over Ethernet networks, includes simple logic control, and powers the whole system. Each
CPU module is equipped with five I/O slots for different I/O modules. The last module slot can be filled by a
backup power module or an additional I/O module.
Product Features
Robust and Compact Design for Harsh Environments
-40 to 75°C operating temperature range
Anti-vibration spring lock terminal block
All-aluminum chassis design
Two LAN ports with M12 or RJ45 connectors for Daisy Chain
The ioPAC Controller has two embedded Ethernet switch ports that allow information to flow to another local
Ethernet device, or to connect to the next ioPAC in the daisy-chain. Applications such as rolling stock passenger
information systems, security systems, and surveillance systems can make use of daisy-chain Ethernet
architecture to build controller networks over standard Ethernet cables. The ioPAC 8020 also provides a
hardware pass-through Ethernet function. This function allows the Ethernet network to continue to function
when an ioPAC in the middle of a daisy-chain goes down. The only limitation is the length of the Ethernet cable,
which cannot be over 100m.

ioPAC 8020 Rugged Remote I/O Introduction
1-3
Hot-swappable I/O modules
The ioPAC modular RTU controller supports a variety of different I/Os with different modules: DC-Digital Input
Modules, Digital Output Modules, Analog Input Modules, Relay Output Modules (coming soon), Temperature
Modules (coming soon), and Analog Output Modules (coming soon).
Auto-detection of Installed Modules
Using Moxa’s utility, the ioPAC automatically detects which modules are installed and displays them
automatically. What you install is what you see. With these built-in LED indicators, it is also easy to identify
which module isn’t in configuration.
Event-based Logic with up to 80 rules and Unicode Active Messages
The ioPAC 8020 controller is an entry level controller with its own private programming language, called
Click&Go™. Click&Go has 80 event-based logic rules built-in to give your ioPAC 8020 the intelligence needed to
control a wide range of applications. All alarm messages support Unicode text.
Built-in Web Console
The ioPAC modular RTU controller includes a built-in web console. You can monitor the I/O status via web
browser
Package Checklist
Each IoPAC 8020 and I/O module is packed securely in a small box.
ioPAC 8020 (if ordered)
•ioPAC 8020 CPU Module with 5 empty I/O slots ×1
•Software and Documentation CD-ROM ×1
•ioPAC 8020 Quick Installation Guide ×1
•Accessories Kit ×1 (3 slot covers, 1 DB9 cover, 1 M12 cover, and one RJ45 cabling kit)
I/O Module (if ordered)
•RM-xxxx I/O module ×1
NOTE: Notify your sales representative if any of the above items are missing or damaged.

ioPAC 8020 Rugged Remote I/O Introduction
1-4
Available Products
ioPAC 8020-5-M12-T: ioPAC 8020 modular RTU controller with dual M12 Ethernet LAN ports and 5 I/O slots,
-40 to 75°C operating temperature
ioPAC 8020-5-RJ45-T: ioPAC 8020 modular RTU controller with dual RJ45 Ethernet LAN ports and 5 I/O slots,
-40 to 75°C operating temperature
RM-1602-T: ioPAC I/O module with 16 digital inputs, 24 VDC sink/source type, -40 to 75°C operating
temperature
RM-1050-T: ioPAC I/O module with 10 digital inputs, 110 VDC, -40 to 75°C operating temperature
RM-2600-T: ioPAC I/O module with 16 digital outputs, 24 VDC sink type, -40 to 75°C operating temperature
RM-3802-T: ioPAC I/O module with 8 analog inputs, 4 to 20 mA, -40 to 75°C operating temperature
RM-3810-T: ioPAC I/O module with 8 analog inputs, 0 to 10 V, -40 to 75°C operating temperature
Product Specifications
Computer
CPU: ARM9 based CPU, 32-bit/160 Mhz
SDRAM: 8 MB
Flash: 4 MB
I/O Scan Time: 100ms
Program Cycle Time: 100ms
Ethernet Interface
LAN: 2 auto-sensing 10/100 Mbps ports (M12 or RJ45)
Ethernet Relay Function: Hardware Normal Close
Serial Interface
Serial Standards: RS-232/422/485 ports (DB9 male)
Serial Signals
RS-232: TxD, RxD, DTR, DSR, RTS, CTS, DCD, GND
RS-422: TxD+, TxD-, RxD+, RxD-, GND
RS-485-4w: TxD+, TxD-, RxD+, RxD-, GND
RS-485-2w: Data+, Data-, GND
Power Requirements
Input Voltage: 12 to 36 VDC
Power Consumption:
CPU Module: 90 mA @ 24 VDC
CPU + I/O Modules: 300 mA @ 24 VDC
Mechanism (5 I/O slot version)
Dimension: 191 x 135 x 100 mm (7.52 x 5.31 x 3.94 in)
I/O Module Slots: 5 or 9 slots
Physical Characteristics
Housing: Aluminum
Mounting: DIN-Rail, wall, rack mounting (with optional kit)
Environmental Limits
Operating Temperature: -40 to 75°C (-40 to 167°F)
Operating Humidity: 5 to 95% RH
Storage Temperature: -40 to 85°C (-40 to 185°F)

ioPAC 8020 Rugged Remote I/O Introduction
1-5
Regulatory Approvals
EMI: FCC part 15, CISPR (EN55022) Class A
EMS:
IEC 61000-4-2 (ESD), level 2/3
IEC 61000-4-3 (RS), level 2
IEC 61000-4-4 (EFT), level 2
IEC 61000-4-5 (Surge), level 3
IEC 61000-4-6 (CS), level 2
IEC 61000-4-8 (PM), level 1
IEC 61000-4-11 (DIP)
IEC 61000-6-2 (ESD), level 2/3
IEC 61000-6-4 (EFT), level 2
Safety: UL508 (Pending)
Shock: IEC 60068-2-27
Freefall: IEC 60068-2-32
Vibration: IEC 60068-2-6
Rail Traffic: EN50155 (Pending), EN50121-3-2 (Pending),
EN50121-4 (Pending)
Note: Please check Moxa’s website for the most up-to-date certification status.
Warranty
Warranty Period: 2 years
Details: See www.moxa.com/warranty

ioPAC 8020 Rugged Remote I/O Introduction
1-6
Physical Dimensions

ioPAC 8020 Rugged Remote I/O Introduction
1-7
Hardware Reference
Panel Guide
NOTE The reset button restarts the server
and resets all settings to factory defaults. Use a pointed object such as
a straightened paper clip to hold the reset button down for 5 seconds
. The READY LED will turn red as you are
holding the reset button down. The factory defaults will be loaded once
the READY LED turns green again. You
may then release the reset button.
LED Indicators for CPU Module
Group Pins/Description Printed label
Ethernet On the Plug
Ready Green: Power On & System working Normally
Green Flashing: Click&Go Active
Interlaced Green/Red Flashing: Safe Mode
Red: System Error
Ready
I/O Off: I/O Module does not exist
Green: Connecting I/O Module and working normally
Green Flashing: Communication
Red: I/O Bus or Modules failure
I/O
Serial Green: Tx
Yellow: Rx
Steady Red: Communication Fail
Serial
Power Green: Normal Input 12 to 36V
Red: Voltage out of range
Off: No Power
Power

ioPAC 8020 Rugged Remote I/O Introduction
1-8
LED Indicators for I/O Modules
Each DIO or AIO module is equipped with a Module Status LED indicating operation status.
LED Name LED Color LED Function
Status Off Not powered or Unknown Module
Green Steady On: System ready.
Flashing: I/O module is in communication.
Red Steady On: I/O module isn’t in configuration.

2
2. Initial Setup
This chapter includes information about installing the ioPAC 8020 and its I/O Modules.
The following topics are covered in this chapter:

Installing the ioPAC on a DIN-Rail
Removing the ioPAC from the DIN-Rail
Grounding the ioPAC System
Inserting/Removing I/O Modules from the ioPAC
Connecting the Power System
Connecting to the Network

ioPAC 8020 Rugged Remote I/O Initial Setup
2-2
System Architecture
The ioPAC 8020 consists of a CPU module that supports Ethernet and up to 5 RM-xxxx-T I/O modules. The
brains of the system is the CPU Module, which collects information from each I/O module and manages their
operation. Communication between the ioPAC 8020 and RM-xxxx-T I/O modules occurs through a Modbus/RTU
communication bus. Modbus Addresses for each I/O channel are fixed by the ioPAC 8020.
The ioPAC 8020 uses 24 VDC power inputs. One power input is required, and a second one can be used as a
backup power input. The ioPAC 8020 provides 5 VDC power to all connected I/O modules. When the total
current consumption of the I/O modules exceeds 1.5A, you will need to insert an extra power module.
Installing the ioPAC on a DIN-Rail
The aluminum DIN-Rail attachment plate should already be fixed to the back panel of the ioPAC 8020 when you
take it out of the box. If you need to reattach the DIN-Rail attachment plate to the ioPAC 8020, be sure the
spring-loaded bracket is situated towards the bottom, as shown in the following figures.
NOTE You can purchase a wall-mounting or rack-mounting kit
separately. The ioPAC 8020 mounting kit is identical
to the one for the EDS-600.
STEP 1: If the spring-loaded bracket is locked in place, push t
he recessed
button to release it. Once released, you should feel some resistance from
the spring as you slide the bracket up and down a few millimeters in each
direction.

ioPAC 8020 Rugged Remote I/O Initial Setup
2-3
STEP 2: Insert the top of the DIN-Rail into the top slots on the DIN-
Rail
attachment plate.
STEP 3: The DIN-Rail attachment unit will snap into place as shown in
the illustration to the right.
Removing the ioPAC from the DIN-Rail
To remove the ioPAC 8020 from the DIN-
Rail, use a screwdriver to push
down the spring-loaded bracket until it locks in place, as shown in the
diagram to the right. Next, rotate the bottom of the switch upwards and
then remove the switch from the DIN-Rail.
Grounding the ioPAC System
The ioPAC 8020 is grounded to enhance EMS performance. The ioPAC 8020
comes with metal DIN-
Rail brackets for grounding the system. For optimal EMS
performance, connect the chassis ground nut on the ioPAC 8020 to the
grounding point. The ground nut is located on the right side of the ioPAC 8020.
Inserting/Removing I/O Modules from the ioPAC
The ioPAC 8020 comes with flexible, hot swappable I/O modules. It is easy to manually tighten and loosen the
screws.

ioPAC 8020 Rugged Remote I/O Initial Setup
2-4
When inserting a new I/O module, follow the steps below:
Step 1: Feed the I/O module into an empty I/O slot with the PCB clip.
Step 2: Push down to the end until the connector is matched.
Step 3: Tighten the I/O module screw.
While removing the I/O module, following the steps below
below
Step 1: Loosen the I/O module screws
Step 2: Remove the I/O module
Connecting the Power System
The ioPAC 8020 requires two 24 VDC power sources. One 24 VDC power input is for system power, and the
other power input is for backup power. We recommended that the two power inputs are connected to different
power supply systems.
ATTENTION
Disconnect the power before installing and wiring
Disconnect the power cord before installing and/or wiring your ioPAC system.
Do not exceed the maximum current for the wiring
Determine the maximum possible current for each power wire and common wire. Observe all electrical codes
dictating the maximum current allowable for each wire size. If the current exceeds the maximum rating, t
he
wiring could overheat, causing serious damage to your equipment.
Connecting to the Network
The ioPAC 8020 supports standard 10/100 Mbps Ethernet. There are two LAN ports (both of which use the same
MAC address) located on the device’s front panel. These two LAN ports are used to connect to Ethernet-enabled
devices. Most users will choose to configure these ports for Auto MDI/MDI-X mode, in which case the port’s
pinouts are adjusted automatically depending on the type of Ethernet cable used (straight-through or
cross-over), and the type of device (NIC-type or HUB/Switch-type) connected to the port. The following section
presents the pinouts for both MDI (NIC-type) ports and MDI-X (HUB/Switch-type) ports. We also give cable
wiring diagrams for straight-through and cross-over Ethernet cables.
10/100BaseT(X) RJ45 Pinouts
MDI Port Pinouts MDI-X Port Pinouts 8-pin RJ45
Pin Signal Pin Signal
1 Tx+ 1 Rx+
2 Tx- 2 Rx-
3 Rx+ 3 Tx+
6 Rx- 6 Tx-
Suggestion For first-time users, we recommend that you link from your host computer to the
ioPAC 8020 over a local
Ethernet network for initial IP and system configuration. Once the installation is complete
, you may move
the entire I/O system to the field. Please note
that you can insert any LAN port to make the configuration
setting work.
Step1. Pick one of the two LAN ports and connect the ioPAC 8020 to the host PC with an Ethernet cable. It
doesn’t matter which port you use. For initial setup of the ioPAC 8020, we assume that the ioPAC 8020 is
configured using a direct connection to a host computer.

ioPAC 8020 Rugged Remote I/O Initial Setup
2-5
Step2. In Windows, you may need to modify the host computer’s IP address to 192.168.127.xxx. (xxx: from
001 to 253) through the Control Panel.
Step3. Connect to the ioPAC 8020’s IP address for configuration. The default IP is as below:
LAN Port Default IP Address Default Netmask Default Gateway
Port 0 /1 192.168.127.254 255.255.255.0 None
There are two ways to configure the ioPAC 8020. One is to use Modular_ioAdmin, the other is to use the web
console. Once the ioPAC 8020 has been detected, modify the settings as needed for your network environment,
then restart the I/O.
3.1: Using Modular_ioAdmin: Please refer to chapter 3 for details.
3.2: Using the web console: Please refer to chapter 4 for details.

3
3. Utilities
This chapter introduces software utilities you can use when configuring the ioPAC modular RTU controller
system. These software utilities include:
•Modular_ioAdmin: The main utility which allows you to configure, monitor, and edit Click&Go™.
•TFTP: The utility which allows you to mass deploy the configuration file.
The following topics are covered in this chapter:
Features of ioAdmin

Modular ioAdmin Main Screen
Main Screen Overview
Functions on the Menu Bar
Watchdog Tab (Administrator)
Click&Go Logic Tab (Administrator)
SNMP Tab (Administrator)

Using TFTP to Import/Export Configuration

ioPAC 8020 Rugged Remote I/O Utilities
3-2
Introduction to Modular_ioAdmin
The ioPAC system may be managed and configured over the Ethernet with Modular_ioAdmin, a Windows utility
provided with your ioPAC 8020. Modular_ioAdmin’s graphical user interface gives you easy access to all status
information and settings. Although ioPAC 8020 also supports configuration by web console, full configuration
and management is only available through Modular_ioAdmin. Modular_ioAdmin includes of following functions:
•Complete function settings
•Click&Go™ Logic
Features of ioAdmin
Auto search and detection
While connected to the ioPAC 8020, the utility can automatically find how many devices are connected on the
network. When you connect successfully, you will see the installed modules on the screen after you login.
You do not need to manually add I/O modules to the configuration one by one. What appears on screen is
exactly what you’ve installed. In addition, it will solve any IP conflicts when you first install two or more ioPAC
8020s to the same network at the same time.
Remote Management
Modular_ioAdmin allows users to find and configure multiple ioPAC 8020 systems over the Ethernet network,
and monitor and configure attached I/O devices. You can also test I/O devices and reset the system.
Click&Go™ Logic Editor
Click&Go™ is an event-based, front-end intelligent logic control system that makes your I/O system smarter.
Modular_ ioAdmin also includes Click&Go logic control for the configuration of your ioPAC system.
Import/Export files:
Modular_ioAdmin allows the import/export of configuration files and device management lists
Modular_ ioAdmin allows the entire configuration of the ioPAC 8020 system to be saved as a file. The file is
viewable as text and can serve as a record or backup of the configuration, or as a template. The file includes file
title, date, time, model information, and Click&Go™ rules.
Modular_ioAdmin can import and export a list of ioPAC 8020 devices that are being managed. This file can
make it easier to manage all devices on the network, and includes server name, module type, IP address, and
unit ID.

ioPAC 8020 Rugged Remote I/O Utilities
3-3
Installing Modular_ioAdmin Utility
Insert the Software CD from the IoPAC 8020’s package into the host computer. Run SETUP.EXE, which is
located in the root directory. The installation program will guide you through the installation process and install
the ioAdmin utility.
After the installation is complete, run Modular ioAdmin from Start Program Files MOXA IO Server 
Utility Modular ioAdmin.
Connecting your ioPAC 8020 system
After you open Modular ioAdmin, the auto search window will pop up and guide you to find the I/O system. Click
“Start Search” to find the I/O system automatically, or you can click “Exit” and then add the ioPAC 8020 system
manually.
If two or more I/O systems with the same IP address are found, Modular_ioAdmin will ask you to modify the IP
address in a pop up window, and then reboot the I/O system. If multiple ioPAC 8020 units are installed on the
same network, remember that each unit has the same default IP address. You will need to assign a different IP
address to each unit to avoid IP conflicts. Modular ioAdmin automatically detects IP conflicts and gives you a
chance to modify each unit’s IP address in the “IP Address” columns. Click the “Set” button to reboot the
corresponding unit with its new IP address. Click the “Re-Search” button to refresh the list of units found by
Modular_ioAdmin.