ProSoft Technology RS485 User manual

RS485 I/O
Expansion System
June 10, 2015
USER GUIDE

User Guide
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February 18, 2015
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How to Contact Us
ProSoft Technology
5201 Truxtun Ave, 3rd Floor
Bakersfield, CA 93309
[phone]
[phone] (Fax)
http://www.prosoft-technology.com
[email protected]
Copyright © 2015 ProSoft Technology, Inc. All rights reserved.
RS485 I/O Expansion System User Guide
June 10, 2015
ProSoft Technology®Product Documentation
In an effort to conserve paper, ProSoft Technology no longer includes printed manuals with our product
shipments. User Manuals, Datasheets, Sample Ladder Files, and Configuration Files are provided on the
enclosed DVD in Adobe®Acrobat Reader file format (.PDFs). These product documentation files may also be
freely downloaded from our web site: www.prosoft-technology.com

ILX34-MBS User Manual
Page 4 of 36 ProSoft Technology, Inc.
June 10, 2015

ILX34-MBS User Manual
ProSoft Technology, Inc. Page 5 of 36
June 10, 2015
Contents
Your Feedback Please........................................................................................................................3
How to Contact Us..............................................................................................................................3
ProSoft Technology®Product Documentation....................................................................................3
1Preface 7
1.1 Compliances..............................................................................................................8
2System Overview 9
2.1 Highlights...................................................................................................................9
2.2 Hardware.................................................................................................................10
3Specifications 11
3.1 Hardware and System.............................................................................................11
3.2 Safety and Compliance...........................................................................................11
3.3 RS485 Expansion I/O Module.................................................................................12
3.4 Digital I/O Module....................................................................................................12
3.5 4-20 mA I/O Module................................................................................................13
3.6 0-10 V I/O Module...................................................................................................13
3.7 Ordering Information ...............................................................................................13
4Installation 15
4.1 Outdoor Enclosure Installation................................................................................15
4.2 RS485 I/O Expansion System Assembly................................................................16
4.3 RS485 Daisy-Chain Diagram..................................................................................20
4.4 Detaching Components from the DataRail..............................................................21
5Wiring Diagrams 23
5.1 RS485 I/O Expansion Module.................................................................................23
5.2 Digital Module..........................................................................................................24
5.3 Analog 4-20 mA Module..........................................................................................25
5.4 Analog 0-10 V Module.............................................................................................26
6Modbus Mapping 27
6.1 Supported Modbus Function Codes........................................................................27
6.2 Digital I/O Module –Modbus Mapping Table..........................................................27
6.3 4-20 mA I/O Module - Modbus Mapping Table.......................................................28
6.4 0-10 V I/O Module - Modbus Mapping Table..........................................................29
7Diagnostics 31
7.1 Radio Module ..........................................................................................................31

ILX34-MBS User Manual
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June 10, 2015
8Frequently Asked Questions 33
9Support, Service & Warranty 35
9.1 Warranty Information .............................................................................................. 36

Preface
ProSoft Technology, Inc. Page 7 of 36
June 10, 2015
1 Preface
Thank you for choosing the RS485 I/O Expansion System. This I/O expansion
solution is designed for use with any Modbus RS485 Master device as a
standalone system. This System follows the Modbus Application Protocol
Specification, v1.1b3, for Data Encoding with values represented in Big-Endian
format or MSB first (word order).
Digital/Discrete, Analog 4-20 mA, or Analog 0-10 V are available for use with the
RS485 I/O Expansion System. This System provides fast, accurate, reliable I/O's
and requires no software programming, making it extremely easy and quick to
use.
To interface with a RS485 Master device, the System utilizes a RS485 I/O
Expansion Module that transfers I/O signals between Modbus Master and
connected I/O Modules. The RS485 Module also distributes power to the I/O
Modules allowing for single point power termination.
This document is designed to guide you through setting up the system by
familiarizing you with the hardware, installation, wiring, and overall system
management.
ProSoft Technology
5201 Truxtun Ave, 3rd Floor
Bakersfield, CA 93309
[phone]
[phone] (Fax)
http://www.prosoft-technology.com
[email protected]

Preface
Page 8 of 36 ProSoft Technology, Inc.
June 10, 2015
1.1 Compliances
Changes or modifications not expressly approved by the manufacturer may
void the user’s authority to operate the equipment.
Warning: Ensure system installation meets applicable state and national electrical code
requirements. The installation of the system should only be performed by a qualified installer or a
factory representative.
Warning: To prevent ignition of flammable or combustible atmospheres, disconnect power before
servicing.
Caution: The RS485 I/O Expansion System must be installed within an enclosure that requires a
tool to access. This is to prevent inadvertent disconnection of any of the power wiring, signal wiring
or communication cables.
Caution: EXPLOSION HAZARD. Do not disconnect equipment unless power has been switched
off or the area is known to be non-hazardous.
Caution: EXPLOSION HAZARD. Do not remove or replace fuse when energized.
Note: This equipment is designed for use in Class I, Division 2 (Zone 2) or non-hazardous
locations only.

System Overview
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June 10, 2015
2 System Overview
2.1 Highlights
Local I/O expansion solution for use with any RS485 Modbus Master device.
System utilizes a pass-through RS485 Interface/Module for transferring I/O signals
between Modbus Master and connected I/O Modules
One RS485 Expansion I/O Module supports multiple Wireless I/O Modules.
System can support up to sixteen (16) Digital Modules
System can support up to eight (8) 0-10 V Modules
System can support up to five (5) 4-20 mA Modules
When adding more than five (5) I/O Modules and mixing different I/O
Modules, please determine maximum allowable I/O Module combination per
system by utilizing the power budget calculator: http://psft.com/A7U
Supports Digital, 0-10 V, and 4-20 mA Modules in any combination.
Each I/O Module provides field isolated inputs and outputs.
Easy to use: no software configuration required.
System attaches onto 35 mm x 7.5 mm DIN rail with easy, clip-on mounting system.
Reduced wire clutter: single power termination.
Wiring label provided on each Module for quick reference.
All Modules are color-coded for quick reference and identification.
The same I/O Modules can also be used for wireless application with Wireless I/O
Radio Kit.
Reduced wire clutter: single power termination.
Quick wiring reference label provided on each Module.
Wireless I/O System can support multiple I/O Modules.
System can support up to sixteen (16) Digital Modules max.
System can support up to eight (8) 0-10 V Modules max.
System can support up to five (5) 4-20 mA Modules max.
Warning: When adding more than five (5) I/O Modules and mixing different I/O Module
combinations, please determine the maximum allowable I/O Module combination per system by
utilizing the power budget calculator. See http://psft.com/A7U

System Overview
Page 10 of 36 ProSoft Technology, Inc.
June 10, 2015
2.2 Hardware
1. RS485 I/O Expansion Module: BM-1000-PM1 (US), BM-0915-RM1 (Int),
BM-2400-RM1 (US), BM-2410-RM1 (Int)
2. Digital Module: BM-D100-144 (US); BM-D100-244 (International)
3. 4-20 mA Analog Module: BM-A420-122 (US); BM-A420-122 (International)
4. 0-10 V Analog Module: BM-A010-122 (US); BM-A010-122 (International)
5. DataRail attaches onto 35 mm x 7.5 mm DIN rail (Standard length included in Radio Kit can
support 1 RS485 I/O Expansion Module + 5 I/O Modules)
6. End Terminal Bracket for securing DataRail and Modules to DIN Rail
7. DataRail Cover for protecting empty DataRail slots

Specifications
ProSoft Technology, Inc. Page 11 of 36
June 10, 2015
3 Specifications
3.1 Hardware and System
HARDWARE & SYSTEM
Unique Features
Works with Any Modbus RS485 Master Device
No Software Configuration Required
Single Point Power Termination
Maximum Network Capacity*
System can support up to sixteen (16) Digital Modules max
System can support up to eight (8) 0-10 V Modules max
System can support up to five (5) 4-20 mA Modules max
When adding more than five (5) I/O Modules and creating different
I/O Module combinations, please determine maximum allowable I/O
Module combination per system by utilizing the power budget
calculator.
Power Budget Calculator
http://psft.com/A7U
Data Encoding Method
MSB First
I/O Module Slave ID Selection
16-Position Rotary Switch (+1 for Modbus Slave ID)
DIN Rail Mounting Compatibility
35 mm x 7.5 mm DIN Rail
DataRail™ (Included w/ Kit)
6.1" / 156 mm - Supports Up to Exp. + 5x I/O Modules
Auto-Detection of Modules
Yes, via DataRail at Power-Up
DataRail Mounting Hardware
4-Claw Attachment to 35 mm DIN Rail with End Terminal Bracket
Built-In Mounting Hardware
Spring-Loaded Clip-On System
Wire Gauge
Solid / Stranded (AWG) 28-12 Gauge
Wire Rating
UL: 300 V RMS, 80 °C and 300 V, 105 °C
CSA: 300 V RMS, 105 °C
Warranty
2-Year Limited
3.2 Safety and Compliance
SAFETY & COMPLIANCE
RADIO
Operational Temperature
-40 °C to 85 °C / -40 °F to 185 °F
Ambient Temperature
-20 °C to 85 °C / -4 °F to 185 °F
Humidity
0 to 99 %, Non-condensing
Degree of Protection / Housing Type
IP20 / Plastic
Hazardous Locations Classifications
Class I; Division 2 (Zone 2), Pending

Specifications
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June 10, 2015
3.3 RS485 Expansion I/O Module
RS485 Expansion I/O Module
Baud Rate
9600 bits per second
Data Bits
8
Parity / Stop Bits
None / 1
RS485 Modbus Slave Addressing
Interface Supports up to 16 Addresses / I/O Modules*
Red LED (Left)
Power
Green LED (Right)
USB-Ready (For Firmware Update)
Supply Voltage Range
9 - 30 VDC (± 5 %)
Protection Against Polarity
Yes
Power Consumption
Typical: 20 mA / Max: 24 mA @12 VDC
Packaging Dimensions (WxHxD)
5.5 x 10.1 x 2.8-in / 140 x 257 x 72mm
Net Dimensions (WxHxD)
0.7 x 3.9 x 4.5-in / 17.5 x 99 x 114mm
Packaging Weight
0.8 lbs / 363 g
Net Weight
0.3 lbs / 136 g
3.4 Digital I/O Module
Digital I/O Module
Number of Inputs
4
Number of Outputs
4
Isolation Voltage
2500 V r.m.s.
Input Voltage Range
3-30 VDC
Input Voltage Threshold
1 Signal ("H"): > 2.3 VDC
0 Signal ("L"): < 1.1 VDC
Output Rating
1 A Sink Current for Open-Drain Outputs / NPN
Green LEDs
Input Indicators
Red LEDs
Output Indicators
Power Consumption
Typical: 18 mA / Max: 26 mA @12 VDC
Packaging Dimensions
(WxHxD) 4.8 x 5.1 x 2.8-in / 123 x 129 x 72mm
Net Dimensions
0.7 x 3.9 x 4.5-in / 17.5 x 99 x 114mm
Packaging Weight
Single: 0.5 lbs / 227 g; Double: 0.8 lbs / 363 g
Net Weight (Single)
0.3 lbs / 136 g

Specifications
ProSoft Technology, Inc. Page 13 of 36
June 10, 2015
3.5 4-20 mA I/O Module
Analog 4-20 mA I/O Module
Number of Inputs
2 (24-bit Resolution)
Number of Outputs
2 (16-bit Resolution)
Isolation Voltage
2500 V r.m.s.
Signal Range
4 mA to 20 mA
Accuracy
< 0.28 % of Full Scale
Internal Loop Power
+13.5 VDC
AI Input Impedance (loop)
128 Ohm
AO Terminal Voltage Range
10 VDC Min. / 31.5 VDC Max.
Power Consumption
Typical: 50 mA / Max: 75 mA @12 VDC
Packaging Dimensions
(WxHxD) 4.8 x 5.1 x 2.8-in / 123 x 129 x 72mm
Net Dimensions
0.7 x 3.9 x 4.5-in / 17.5 x 99 x 114mm
Packaging Weight
Single: 0.5 lbs / 227 g; Double: 0.8 lbs / 363 g
Net Weight (Single)
0.3 lbs / 136 g
3.6 0-10 V I/O Module
Analog 0-10 V I/O Module
Number of Inputs
2 (24-bit Resolution)
Number of Outputs
2 (16-bit Resolution)
Isolation Voltage
2500 V r.m.s.
Signal Range
0 VDC to 10 VDC (10.5 V Max)
Accuracy
< 0.1 % of Full Scale
AI Input Impedance
40K Ohm
AO Output Impedance
10 Ohm
Power Consumption
Typical: 40 mA / Max: 45 mA @12 VDC
Packaging Dimensions
(WxHxD) 4.8 x 5.1 x 2.8-in / 123 x 129 x 72mm
Net Dimensions
0.7 x 3.9 x 4.5-in / 17.5 x 99 x 114mm
Packaging Weight
Single: 0.5 lbs / 227 g; Double: 0.8 lbs / 363 g
Net Weight (Single)
0.3 lbs / 136 g
3.7 Ordering Information
ORDERING INFORMATION
RS485
RS485 Expansion Kit
BM-1000-PM1K
Kit Content
RS485 Expansion I/O Module, DataRail,
2x End Terminal Brackets, DataRail Cover,
Quick Start Guide, Technician's Screwdriver
Digital I/O
1-Pack: BM-D100-144S
2-Pack: BM-D100-144D
4-20 mA I/O
1-Pack: BM-A420-122S
2-Pack: BM-A420-122D
0-10 V I/O
1-Pack: BM-A010-122S
2-Pack: BM-A010-122D

Specifications
Page 14 of 36 ProSoft Technology, Inc.
June 10, 2015

Installation
ProSoft Technology, Inc. Page 15 of 36
June 10, 2015
4 Installation
4.1 Outdoor Enclosure Installation
1. Install or use existing outdoor NEMA-type enclosure.
2. Be sure the RS485 I/O Expansion System meets applicable grounding requirements
in the enclosure.
3. Install a 35 mm x 7.5 mm DIN rail (at least 166 mm (6.5-inch) wide) inside the
enclosure.
4. Provide external power supply: 9-30 VDC.
5. Make a hole on the bottom of the enclosure to run wires.
6. Run conduit for power and I/O cabling.
7. Feed power wiring into enclosure.
8. Terminate RS485 wiring.

Installation
Page 16 of 36 ProSoft Technology, Inc.
June 10, 2015
4.2 RS485 I/O Expansion System Assembly
Warning: Power must be disconnected or turned off prior to attaching or removing any I/O
Modules from the system –failure to comply may cause damage hardware.
1. Securely attach the DataRail onto a 35 mm x 7.5 mm DIN rail by gently
pressing on all four (4) corner clips.
2. Secure DataRail to DIN rail by attaching an End Terminal Bracket.
a. First, hook the metal end of the Bracket to DIN rail and then snap the
other end onto the DIN rail. (Make sure to position the Bracket on the far
left of the DataRail where metal blades meet the plastic).

Installation
ProSoft Technology, Inc. Page 17 of 36
June 10, 2015
3. Attach RS485 I/O Expansion Module to DataRail (place it next to the Bracket
without any gap).
a. First, latch the top hook onto the rail, then snap-in the spring-loaded clip
into place.
4. Attach I/O Module(s) to the system.
a. Place Modules in any combination (do not leave gaps between Modules).
b. When using more than five (5) I/O Modules, determine maximum I/O
Module combination by using power budget calculator: http://psft.com/A7U
c. Use the 16-position switch located on the front of each I/O Module to set
the Modbus Slave ID(s). Slave ID = Switch position number + 1.
Ex: Switch ID 0 + 1 = Slave ID 1

Installation
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June 10, 2015
5. Attach the other End Terminal Bracket to secure the Modules. (Place it next
to the last module without leaving a gap)
6. Protect any unused DataRail slots with the cover. Snap-off extra pieces and
store for future use.
7. Terminate the RS485 terminals.

Installation
ProSoft Technology, Inc. Page 19 of 36
June 10, 2015
8. Terminate I/O and supply power as required. Use solid or stranded wire
(AWG) 28-12.

Installation
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4.3 RS485 Daisy-Chain Diagram
1. If more I/O Modules are required, another RS485 I/O Expansion Module (Kit) set
can be deployed simply using the daisy-chain method.
2. The System holds up to 16 I/O Module Slave addresses regardless of the number
of RS485 I/O Expansion Modules deployed.
3. Each Module must be set to a unique Modbus Slave address.