Moxa Technologies ioPAC 8500 series Instructions for use

ioPAC 8500 Hardware User’s Manual
First Edition, November 2013
www.moxa.com/product
© 2013 Moxa Inc. All rights reserved.

ioPAC 8500 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
© 2013 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
www.moxa.com/support
Moxa
Americas
Toll
-free: 1-888-669-2872
Tel:
[phone]
Fax:
[phone]
Moxa China (Shanghai office)
Toll
-free: 800-820-5036
Tel:
[phone]
Fax:
[phone]
Moxa Europe
Tel:
[phone]
Fax:
[phone]
Moxa As
ia-Pacific
Tel:
[phone]
Fax:
[phone]
Moxa India
Tel:
[phone]
Fax:
[phone]

Table of Contents
1. Introduction...................................................................................................................................... 1-1
Overview ...........................................................................................................................................1-2
Package Checklist ............................................................................................................................... 1-2
2. Installation ....................................................................................................................................... 2-1
Basic Installation ................................................................................................................................ 2-2
DIN Rail Installation Procedure......................................................................................................2-2
Module Installation Procedure (Power-Off)......................................................................................2-3
Module Installation Procedure (Power-On) ......................................................................................2-3
Configuring the Power ......................................................................................................................... 2-4
Powering on the ioPAC Controller ..................................................................................................2-4
Grounding the ioPAC....................................................................................................................2-4
Installing a microSD Card ....................................................................................................................2-5
Connecting to the Network................................................................................................................... 2-6
Ethernet Communication .............................................................................................................. 2-6
Serial Connectivity ..............................................................................................................................2-8
Connecting to a Serial Device .......................................................................................................2-8
Serial Console (Debug Port)..........................................................................................................2-8
Battery............................................................................................................................................ 2-11
3. ioPAC 8500 Hardware Introduction................................................................................................... 3-1
Appearance and Dimensions ................................................................................................................3-2
Appearance ................................................................................................................................ 3-2
Dimensions.................................................................................................................................3-2
Hardware Block Diagrams.................................................................................................................... 3-4
ioPAC 8500 CPU Board Block Diagram............................................................................................3-4
Product Hardware Specifications ...........................................................................................................3-5
Product Selection Guide ...............................................................................................................3-5
Product Specifications ..................................................................................................................3-5
ioPAC 8500 LED Indicators...................................................................................................................3-7
System LEDs ..............................................................................................................................3-7
Communication LEDs ...................................................................................................................3-8
User-Defined LEDs: LED1 and LED2...............................................................................................3-8
Toggle Switch: Mode 1 and Mode 2 .......................................................................................................3-9
Toggle Switch: Factory Reset Process....................................................................................................3-9
4. 85M Module Hardware Introduction.................................................................................................. 4-1
85M Module Descriptions .....................................................................................................................4-2
Common Specifications .......................................................................................................................4-2
Module Specifications ..........................................................................................................................4-3
85M-1602-T: Digital Input, 24 VDC, Sink/Source, Dry Contact Type ..................................................4-3
85M-2600-T: Digital Output, 24 VDC, Sink Type .............................................................................4-5
85M-38XX-T: Analog Input ...........................................................................................................4-7
85M-5401-T: Serial Ports ........................................................................................................... 4-12

1
1. Introduction
The following topics are covered in this chapter:

Overview

Package Checklist

ioPAC 8500 Hardware Introduction
1-2
Overview
The ioPAC 8500 modular type controllers use an ARM9 based industrial grade CPU for the system, with ARM
Cortex™ M4 based CPUs used for the modules. The controllers have 2, 5, or 9 I/O slots for 85M series modules.
The USB bus between the controller CPU and module CPUs transmits data at up to 200 Mbps, and the dual CPU
architecture supports a 40 kHz analog input sampling rate, pre-recording of analog input data, and millisecond
timestamp. The ioPAC 8500 supports C/C++ programming capability, rail-level surge and ESD protection, a
-40 to 75°C operating temperature range, anti-vibration, hot-swappability of modules, 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 8500 series provides a comprehensive solution for data acquisition and
control applications in harsh environment.
Package Checklist
ioPAC 8500
The ioPAC 8500 is shipped with the following items:
•ioPAC 8500 controller
•Serial console cable
•Documentation and software CD
85M Modules
85M modules are shipped with the following items:
•85M module
•DB44 to 4-port DB9 cable included in 85M-5401-T package
Optional Accessories (can be purchased separately)
•WK-75: Wallmount kit
•CBL-M12D(MM4P)/RJ45-100 IP67: M12 to RJ45 cable
•85M-BKTES: Empty slot cover for ioPAC 85xx modules (3 pcs per package)

2
2. Installation
This chapter includes instructions on how to install the ioPAC 8500.
The following topics are covered in this chapter:

Basic Installation
DIN Rail Installation Procedure
Module Installation Procedure (Power-Off)
Module Installation Procedure (Power-On)

Configuring the Power
Powering on the ioPAC Controller
Grounding the ioPAC

Installing a microSD Card

Connecting to the Network
Ethernet Communication

Serial Connectivity
Connecting to a Serial Device
Serial Console (Debug Port)

Battery

ioPAC 8500 Hardware Installation
2-2
Basic Installation
DIN Rail Installation Procedure
Installing the ioPAC 8500 on a DIN Rail
The DIN rail attachment plate should already be fixed to the back panel of the ioPAC 8500 when you take it out
of the box. If you need to reattach the DIN rail attachment plate to the ioPAC 8500, be sure the spring-loaded
bracket is situated towards the bottom, as shown in the figures below.
NOTE
A wall
mount kit can be purchased separately.
STEP 1:
If the spring-
loaded bracket is locked in place, push the
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.
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 below.
Removing the ioPAC 8500 from a DIN Rail
To remove the ioPAC 8
50
0 from a DIN rail, use a screwdriver to push down
the spring
-
loaded bracket until it locks in place, as shown in the diagram at
the right. Next, rotate the bottom of the switch upwards and then remove the
switch from the DIN rail.

ioPAC 8500 Hardware Installation
2-3
Module Installation Procedure (Power-Off)
Moxa’s ioPAC 8500 controllers come with 2, 5, or 9 slots for 85M-series modules. Use the following procedure
to install modules when your system is powered off.
Step1: Install the module into the ioPAC 8500 system. The module’s PCB should align with the edge of the
frame. Push the module into the slot and make sure the module is plugged into the backplane.
Step2:Fasten the two screws using 3.5±0.5 kg of torque.
Module Installation Procedure (Power-On)
All ioPAC 8500 modules are hot-swappable, which means that you can safely install, remove, and replace
modules while the system is powered on. When a module is removed or installed when the system is powered
on, the module head stops processing and registers the newly installed or recently removed module, and scans
for a configuration change. There is no disruption to normal operation during module insertion or removal.
After installing a new module, it could take about ten seconds for the system to recognize and activate the
module, at which point the module’s LED will turn green.
WARNING
When the system is
powered on
, do not install more than one module at a time. If you need to install multiple
modules, wait until the most
recently installed module’s LED turns GREEN before installing the next module.

ioPAC 8500 Hardware Installation
2-4
Configuring the Power
Powering on the ioPAC Controller
The ioPAC controller can receive power from a 9 to 48 VDC power source, and is
compliant with EN 50155 at 24 VDC. Input power is applied to the positive (V+) and
negative (V
-) terminals on the connector.
•
When the input voltage is below the minimum recommen
ded 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.
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
isolated power supply with design based on the EN 5
0155 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 8500 Hardware Installation
2-5
Installing a microSD Card
The ioPAC is equipped with one slot for microSD cards. 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 cards. 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 the 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 8500 Hardware Installation
2-6
Connecting to the Network
Ethernet Communication
Connections to the LAN port are made through an RJ45 or M12 connector on the module. The wiring and pin
connections for these connectors are described in separate sections below.
•TCP/IP Settings: Dual Speed Functionality: The ioPAC 8500’s Ethernet ports auto negotiate with the
connected devices and then use the fastest data transmission rate supported by both devices. The following
table shows the TCP/IP parameters supported by the LAN port. Default values are set when a Factory Reset
is performed on the controller.
Lan Port 1 Lan Port 2
Parameter Supported Values Parameter Supported Values
IP Address Default: 192.168.127.254 IP Address Default: 192.168.126.254
Subnet Mask Default: 255.255.255.0 Subnet Mask Default: 255.255.255.0
Gateway Default: 0.0.0.0 Gateway Default: 0.0.0.0
IP Address is the IP address of the controller.
Subnet Mask determines the subnet on which the controller is located.
Gateway determines how your controller communicates with devices outside its subnet. Enter the IP
address of the gateway.
The IP address, subnet mask, and gateway are static; contact your network administrator to obtain these
addresses for the controller.
RJ45 Ethernet Connector
The ideal maximum cable length of a 10/100BaseT connection is 100 m (350 feet), but the actual limit could be
longer or shorter depending on the amount of electrical noise in the environment. To minimize the amount of
noise, Ethernet cables should not run parallel to power cables or other types of cables that generate electrical
noise.
The following diagram and table shows the pin connections for the RJ45 Ethernet connector.
RJ45 Connector Pin Assignment
Contact Media Direct Interface Signal
1 Tx + (transmit)
2 Tx - (transmit)
3 Rx + (receive)
4 Not used
5 Not used
6 Rx - (receive)
7 Not used
8 Not used
M12 Ethernet Connector
The ioPAC 8500 has two 10/100BaseT(X) Ethernet ports that use 4-pin shielded M12 connectors with D coding.
The 10/100T(X) ports located on the front panel of ioPAC 8500 are used to connect to Ethernet-enabled devices.
Most users configure these ports for Auto MDI/MDI-X mode, in which case the port’s pinouts are adjusted

ioPAC 8500 Hardware Installation
2-7
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 Auto MDI/MDI-X function (M12 connector) allows users to connect the ioPAC 8500’s 10/100BaseTX
ports to any kind of Ethernet device, without needing to pay attention to the type of Ethernet cable being
used for the connection. This means that you can use either a straight-through cable or cross-over cable to
connect the ioPAC 8500 to Ethernet devices.
The following diagram and table shows the pin connections for the M12 Ethernet connector.
M12 Ethernet Connector Pin Assignments
Male Wire-Color Bus Reference
1 Orange (+) B
2 Not used n.c –
3 – Shield S
4 Blue -1 A
In what follows, we give 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.
M12 (4-pin, M) to M12 (4-pin, M) Cross-Over Cable Wiring
M12 (4-pin, M) to M12 (4-pin, M) Straight-Through Cable Wiring
M12 (4-pin, M) to RJ45 (8-pin) Cross-Over Cable Wiring
M12 (4-pin, M) to RJ45 (8-pin) Straight-Through Cable Wiring

ioPAC 8500 Hardware Installation
2-8
ATTENTION
Configuring the two LAN ports on the same ioPAC RTU controller to the same network domain (e.g.,
192.168.1.1 and 192.168.1.2) is not recommended.
Port Trunking
The ioPAC 8500 RTU controller has a Port Trunking function (active backup mode) that can convert two
LAN-port IP addresses into one virtual IP address for easy SCADA integration and Ethernet redundancy. In the
following diagram, both LAN ports on each ioPAC RTU controller are connected to a managed switch on an
Ethernet network running SCADA software. For more details regarding configuration setup, refer to the ioPAC
RTU Software User’s Manual.
Serial Connectivity
Connecting to a Serial Device
The ioPAC RTU is equipped with two 3-in-1 serial ports that support RS-232/422/485, making it more
convenient to connect field serial devices.
Pin RS-232 RS-422 and 4-wire RS-485 2-wire RS-485
1 DCD TxD-(A) –
2 RXD TxD+(B) –
3 TXD RxD+(B) Data+(B)
4 DTR RxD-(A) Data-(A)
5
GND
GND
GND
6 DSR – –
7 RTS – –
8 CTS – –
9 RI – –
Serial Console (Debug Port)
The serial console gives users a convenient way of connecting to the RTU controllers. This method is
particularly useful when using the computer for the first time. The serial console is also effective for connecting
the Moxa RTU controllers when you do not know target network settings and IP addresses.

ioPAC 8500 Hardware Installation
2-9
Step 1: To use the serial console, remove the cover from the front/top panel first.
Console Port for the ioPAC Series
Step 2: Attach the 4-pin serial console cable to the console port. The following diagram shows the 4-pin serial
connector and pin connections.
Pin Assignment for the Serial Console Port
Pin Definition
1 TxD
2 RxD
3 NC
4 GND
Serial Console Default Settings
Parameter Value
Baudrate 115200 bps
Parity None
Data bits 8
Stop bits 1
Flow Control None
Terminal VT100
We recommend using Moxa PComm Terminal Emulator to connect to the serial console. The following steps
describe how to connect the console.
1. Download Moxa PComm Lite from the Moxa website (www.moxa.com) or copy it from the following folder
on the Documentation and Software CD: Software\utility\PComm\.
2. Install Moxa PComm Lite to the host Windows PC.
3. Run PComm Lite Terminal Emulator from Start Programs PComm Lite Ver 1.x Terminal
Emulator.
4. Click Profile Open.

ioPAC 8500 Hardware Installation
2-10
5. Specify which COM port is connecting to the Moxa RTU, and use the following configuration settings: 115,
200, 8, none, 1.
6. Click on the Terminal tab and configure the Terminal Type to VT100. Click OK to proceed.
7. The serial console will be displayed on the terminal screen.

ioPAC 8500 Hardware Installation
2-11
Battery
The ioPAC RTU controller is equipped with one built-in, rechargeable VL2020 3V battery for the SRAM and one
BR2032 3V non-rechargeable battery for the Real Time Clock (RTC).
•Rechargeable battery (VL2020) for SRAM
Sustains at least 1 week without power supply
Capacity: 20 mAh
Typical consumption (@ 25°C): 4 μA
5-year warranty
•Non-rechargeable battery (BR2032) for RTC
Sustains at least 5 years without power supply
Capacity: 195 mAh
Typical consumption (@ 25°C): 2 μA
5-year warranty
Caution
Do
NOT attempt to replace the battery. Contact your local dealer for replacement assistance.

3
3. ioPAC 8500 Hardware Introduction
This chapter introduces the ioPAC 8500’s hardware specifications.
The following topics are covered in this chapter:

Appearance and Dimensions
Appearance
Dimensions

Hardware Block Diagrams
ioPAC 8500 CPU Board Block Diagram

Product Hardware Specifications
Product Selection Guide
Product Specifications

ioPAC 8500 LED Indicators
System LEDs
Communication LEDs
User-Defined LEDs: LED1 and LED2

Toggle Switch: Mode 1 and Mode 2

Toggle Switch: Factory Reset Process

ioPAC 8500 Hardware ioPAC 8500 Hardware Introduction
3-2
Appearance and Dimensions
Appearance
ioPAC 8500 Modular Head
The following figures depict ioPAC 8500 modular heads. There are two types of modular heads, both have dual
Ethernet ports but one is RJ45 and the other is M12.
Dimensions
ioPAC 8500-2
Unit: mm (inch)

ioPAC 8500 Hardware ioPAC 8500 Hardware Introduction
3-3
ioPAC 8500-5
Unit: mm (inch)
ioPAC 8500-9
Unit: mm (inch)

ioPAC 8500 Hardware ioPAC 8500 Hardware Introduction
3-4
Hardware Block Diagrams
ioPAC 8500 CPU Board Block Diagram