Qube Solutions PiXtend eIO Series User manual
PiXtend eIO Hardware Manual
Version History
Version Date Description Editor
1.05 18.10.19 First publication TG
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PiXtend eIO Hardware Manual
Table of Contents
1. About this Documentation..................................................................................................5
1.1. Scope..........................................................................................................................5
1.2. Cop right.....................................................................................................................5
1.3. Names, Brands, Wordmarks and Images...................................................................6
1.4. S mbols......................................................................................................................7
1.4.1. General S mbols................................................................................................7
1.4.2. Special Warning S mbols..................................................................................8
2. Important Information.........................................................................................................9
2.1. Subject to Change......................................................................................................9
2.2. Intended Use..............................................................................................................9
2.3. Technical Condition...................................................................................................11
2.4. Certificates................................................................................................................12
2.5. Safet Instructions....................................................................................................13
2.6. Disclaimer.................................................................................................................14
2.7. Contact Information..................................................................................................14
2.8. Assistance.................................................................................................................14
3. Basic Knowledge..............................................................................................................15
3.1. Power Suppl ............................................................................................................16
3.2. Bus Topolog & Wiring..............................................................................................19
3.3. Bus Lines..................................................................................................................22
4. Scope of Deliver .............................................................................................................24
4.1. PiXtend eIO Digital One Basic..................................................................................25
4.2. PiXtend eIO Digital One Pro.....................................................................................26
4.3. PiXtend eIO Analog One Basic.................................................................................27
4.4. PiXtend eIO Analog One Pro....................................................................................28
4.5. Accessories...............................................................................................................29
4.5.1. Cable Set – without Termination........................................................................29
4.5.2. Cable Set – with Termination.............................................................................30
4.5.3. RS485-USB dongle...........................................................................................31
5. Startup..............................................................................................................................32
5.1. Setting Switch Positions...........................................................................................33
5.2. Setting Jumpers........................................................................................................47
5.2.1. Jumpers for PiXtend eIO Digital One................................................................49
5.2.2. Jumpers for PiXtend eIO Analog One...............................................................50
5.3. Protective Conductor Connection.............................................................................51
5.4. Connect Suppl Voltage...........................................................................................54
5.5. Connection of Alternative Power Supplies...............................................................58
5.6. Connection to a Bus Master.....................................................................................60
5.6.1. PiXtend V2 -L- as Master..................................................................................61
5.6.2. PC with USB-RS485 Dongle as Master............................................................64
5.7. Troubleshooting........................................................................................................67
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6. Technical Data & Connection Notes................................................................................69
6.1. Overview - Connections & Functions.......................................................................69
6.2. Information about the Overall S stem......................................................................70
6.2.1. Mechanics.........................................................................................................71
6.2.2. Terminal Blocks.................................................................................................74
6.2.3. Power Suppl ....................................................................................................75
6.2.4. LED Signaling....................................................................................................79
6.3. RS485.......................................................................................................................82
6.4. PiXtend eIO Digital One............................................................................................88
6.4.1. Digital Inputs......................................................................................................89
6.4.2. Digital Outputs...................................................................................................94
6.5. PiXtend eIO Analog One..........................................................................................99
6.5.1. Analog Inputs...................................................................................................100
6.5.2. Analog Outputs................................................................................................110
6.6. Operation with 12V Suppl Voltage........................................................................116
7. List of Figures.................................................................................................................117
8. Table director ................................................................................................................119
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PiXtend eIO Hardware Manual
1. bout this Documentation
Save this Documentation!
This documentation is part of the product and is to be kept for the entire duration of the
products usage. If the product is passed on or sold, this document must be handed over to
the next user, this also include an extensions to this documentation.
1.1. Scope
This documentation applies onl to the software components specified in the table of
contents and to PiXtend eIO devices of the following t pes:
- PiXtend eIO Digital One Basic (QS item: 800)
- PiXtend eIO Digital One Pro (QS item: 801)
- PiXtend eIO Analog One Basic (QS item: 810)
- PiXtend eIO Analog One Pro (QS item: 811)
All further documents for these products can be found on our homepage at
http s ://www.pixtend.de/downloads/
1.2. Copyright
This documentation, including all texts and pictures, is protected b cop right. The written
approval of Qube Solutions GmbH, Eningen u.A., GERMANY, must be obtained for an
other use, translation into other languages, archiving or other alteration.
Copyright 2019 © Qube Solutions GmbH
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1.3. Names, Brands, Wordmarks and Images
"Raspberr Pi" and its logo are registered trademarks of the Raspberr Pi Foundation -
www.raspberr pi.org
"CODESYS" and its logo are registered trademarks of 3S-Smart Software GmbH -
www.codes s.com
"PiXtend", "ePLC" and the associated logo are protected trademarks of Qube Solutions
GmbH- www.qube-solutions.de
"AVR", "ATmega" and the associated logo are registered trademarks of Atmel Corporation
- www.atmel.com or Microchip Technolog Corporation www.microchip.com
"Debian" and "Raspbian" are protected trademarks of the Debian Project - www.debian.org
"I2C" or "I²C" are registered trademarks of NXP Semiconductors - www.nxp.com
"Arduino" is a registered trademark of Arduino AG - www.arduino.cc
„Android“ and its logo are registered trademarks of the compan Google LLC -
www.google.com
„Modbus“ and its logo are registered trademarks of the Modbus Organization, Inc. -
www.modbus.org
The rights of all companies and compan names mentioned herein as well as products
and product names lie with the respective companies.
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PiXtend eIO Hardware Manual
1.4. Symbols
1.4.1. General S mbols
Important NOTE!
This s mbol identifies important information to avoid malfunctions and
accidental misuse.
Warning!
This s mbol indicates a warning and can result in damage to propert
if not observed.
Danger!
This s mbol indicates a high hazard which can lead to serious
personal injur or death, if not observed.
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PiXtend eIO Hardware Manual
1.4.2. Special Warning S mbols
Warning of Hot Surface / Risk of Burning!
This s mbol indicates important information to warn the user of
possible burns or heat sources.
Warning of Electrical Voltage / Caution High Voltage!
This s mbol indicates a warning of dangerous electrical voltages.
Non-observance can result in damage to propert and / or personal
injur , including death.
Warning - ESD Endangered Components
This s mbol indicates a warning of electrostatic discharge on sensitive
components.
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PiXtend eIO Hardware Manual
2. Important Information
This chapter contains information about the subject to change topic, the intended use, the
technical condition of the described product, the disclaimer, the safet notices and where
to get help.
2.1. Subject to Change
The compan Qube Solutions GmbH reserves the right to revise or amend this
documentation in whole or in part if this serves the technical progress or if existing
software components have to be changed or new ones have been created. The user will
alwa s find the latest version of this documentation at http s ://www.pixtend.de/downloads/ .
2.2. Intended Use
The PiXtend eIO devices fulfill the function of input and output units for electrical signals.
Sensor signals can be detected, evaluated and actuators activated. The specifications of
the inputs and outputs compl with the international standard for programmable logic
controllers, in short: PLC - IEC / EN 61131-2. In addition, the devices compl with the EMC
requirements of Zone B (general industrial environment) from the cited standard.
Communication between PiXtend eIO and other devices takes place via a serial interface
(RS485 / EIA485). It is a so-called bus s stem in which up to 32 participants can
communicate with each other. PiXtend eIO fulfills the function of a "slave" in such a bus
s stem (also called a network). This means that information can be sent or requested to
devices. A slave alwa s onl becomes active on the bus if it is addressed b a "master", ie
it is requested to communicate. A direct data transfer between the slaves does not take
place. Possible masters for the PiXtend eIO devices are personal computers (PC),
industrial controllers (PLC, IPC), Raspberr Pi computers, Arduino, embedded devices,
speciall equipped smartphones & tablets and man more computer s stems that have an
RS485 interface or can be retrofitted with this kind of interface. In particular, the
combination of PiXtend eIO devices with the PiXtend V2 -L- control should be mentioned.
This is the reference bus master recommended b Qube Solutions.
The PiXtend eIO devices master two protocols - "Modbus RTU" and the "PiXtend eIO
ASCII protocol". Basic settings for operation on the bus (baud rate, parit , stop bits,
address, protocol and terminator) are set using mechanical switches on the device before
use. The intelligence of the modules, data processing, bus communication, I/O control, etc.
is provided b a central microcontroller installed on each of the devices.
The programming of the inputs, outputs and special functions can be done among other
things with the professional software "CODESYS V3" of the compan 3S Smart Software
Solutions GmbH. Qube Solutions also offers other automation, IT and home automation
programming languages and s stems that customers can use to control PiXtend eIO
devices (C, C ++, C #, P thon, Java, FHEM, Node-RED). Information and examples from
Qube Solutions exist for this languages. Both protocols are disclosed and can be
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PiXtend eIO Hardware Manual
implemented b the customer - in their own responsibilit - in other programming
languages and s stems.
Unlike previous Qube Solutions products, the PiXtend eIO devices are delivered
exclusivel as finished devices that are read to use and do not require final assembl b
the customer.
The PiXtend eIO devices are designed for dr indoor environments - protection class IP20
(Pro), IP00 (Basic). Operation outdoors and in damp rooms is not permitted unless the
equipment is installed in a suitable housing. The devices are not designed for potentiall
explosive areas or safet -critical s stems / s stems with particularl high requirements.
PiXtend eIO devices ma be used equall in industrial / commercial, educational and
residential environments.
Intended uses are:
•Machine, plant and equipment construction
•Testers in production compan s
•Laborator and production automation
•Home Automation / Smart Home
•Protot ping in industr (development departments)
•Use in education (technical schools, colleges & universities)
•IoT (Internet of Things), IIoT (Industrial Internet of Things) concepts & solutions
•Industr 4.0 concepts & solutions
•Mobile applications - auxiliar functions in the automotive sector
All PiXtend eIO devices are suitable for persons over the age of 14 who have read and
understood the safet data sheet and the manuals.
In educational institutions, the operation must be supervised b competent and authorized
personnel. The power supplies and accessories used must be approved for the countr in
which the complete PiXtend eIO s stem is to be installed or used.
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PiXtend eIO Hardware Manual
2.3. Technical Condition
Ever PiXtend eIO device, regardless of its variant, is delivered with a defined
configuration:
PiXtend eIO Digital One
•All digital inputs are configured for the 24 V range
(no jumper plugged in)
•Address: 1, baud rate: 19,200 baud, parit bit: even, stop bits: 1 (8E1)
•Termination inactive, Mode / Protocol: Modbus RTU
•The microcontroller firmware alwa s complies with the latest version released b
Qube Solutions. The current version and information about changes ("changelog")
can be found on our Homepage
PiXtend eIO nalog One
•All analog voltage inputs are configured for the 0..10 V range
(no jumper plugged in)
•Address: 3, baud rate: 19,200 baud, parit bit: even, stop bits: 1 (8E1)
•Termination inactive, Mode / Protocol: Modbus RTU
•The microcontroller firmware alwa s complies with the latest version released b
Qube Solutions. The current version and information about changes ("changelog")
can be found on our Homepage
Each device can be ordered in two different versions / variants:
Basic
•Basic version without housing
Pro
•Professional version with stainless steel hood and DIN rail housing
If ou require a different version or a different hardware and software combination, please
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PiXtend eIO Hardware Manual
2.4. Certificates
This product has been designed and manufactured in accordance with applicable
european directives and is therefore marked with the CE sign. The intended use is
described in this document. A safet data sheet is supplied with each product in paper
form (multilingual).
Warning:
Changes and modifications to the product, as well as a non-compliance with the
information contained in the manuals and safet data sheets, will lead to the loss of
certification and approval for the European Economic Area.
WEEE-Reg.-Nr.: DE 15868016
The s mbol of the crossed-out waste bin (WEEE s mbol) means that this product must be
rec cled separatel from an household waste as electrical waste. Where ou can find the
nearest rec cling station, ask our local municipal administration.
You can also return our device to us and we will handle the correct disposal for ou.
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PiXtend eIO Hardware Manual
2.5. Safety Instructions
Read the complete document and the safet and connection notes before ou start the
installation of the PiXtend eIO. Save this document even after ou have commissioned all
components.
Warning
The company Qube Solutions GmbH does not accept any
liability for damage of any kind resulting from disregarding the
data sheets and operating instructions. The guarantee or
warranty claim and the admission expire.
•PiXtend eIO ma onl be operated with the prescribed voltage (19-30 V DC) and a power
suppl with VDE and CE mark (for Europe). The power suppl must compl with the legal
requirements of the countr in which PiXtend is used.
•The device is onl designed for use in dr and clean rooms and is not suitable for outdoor
use or in damp areas.
•The permissible operating temperature is between 0 °C (32 °F) and 60 °C (140 °F).
•PiXtend eIO devices as well as all cables, connectors and power supplies must be kept
awa from liquids.
•PiXtend eIO modules must not be used in the vicinit of flammable liquids, gases or dusts.
•Onl original or recommended spare parts ma be used during repairs. In case of doubt,
alwa s ask Qube Solutions first! - [email protected]
•Neither PiXtend eIO nor the accessories belong in children's hands (under 14 ears).
•In schools, hobb workshops and training facilities, the operation is supervised b trained
personnel.
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PiXtend eIO Hardware Manual
2.6. Disclaimer
The information contained in this documentation has been compiled, checked and tested
with the software and hardware described herein. Nevertheless, deviations can not be
ruled out completel . Qube Solutions GmbH shall not be liable for an damages that ma
result from the use of the software, software components, hardware or the steps described
in this documentation.
2.7. Contact Information
Our postal address:
Qube Solutions GmbH
Arbachtalstr. 6
D-72800 Eningen
GERMANY
How to reach us:
Fax: +49 (0) 7121 2848662
info@pixtend. com
www.pixtend. com
2.8. ssistance
A lot of information, tips and tricks can be found in our support forum at:
http s ://www.pixtend. de /forum/
Should an questions remain unanswered, please first to look in the corresponding
chapters of the manuals and in the FAQ's on our homepage. If the question is not
answer as soon as possible and further information.
The latest versions of all documents and software components can be found in the
download area of our homepage: https://www.pixtend.de/downloads/
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PiXtend eIO Hardware Manual
3. Basic Knowledge
In this chapter basic knowledge is taught, which is needed for the use of PiXtend eIO. The
sub-areas Power Supply (page 16), Bus Topology & Wiring (page 19) & Bus Lines (page
22) are described in detail.
Especiall if ou have no or onl little experience with RS485 bus s stems, the following
information is important for the safe and reliable operation of PiXtend eIO devices.
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PiXtend eIO Hardware Manual
3.1. Power Supply
All PiXtend eIO devices are operated with a nominal suppl voltage of 24 V (DC voltage).
The exact specifications and connection instructions for a suitable power suppl can be
found in chapters 5.4 Connect Supply Voltage and 6 Technical Data & Connection Notes.
This is about the topolog of powering several eIO devices in a RS485 bus / network.
Figure 1 shows the correct wiring or power suppl topolog for multiple PiXtend eIO
devices. Each device is approached separatel from a common suppl or ground point
with its own lines.
The conductor cross-section, especiall of the ground lines, should be much larger than
the signal lines for the RS485 bus. This has the background that the suppl current of the
modules (comparativel large current) should be dissipated via the suppl connection and
not via the GND connection, which belongs to the RS485 network.
Ideall , a separate power suppl is used for the digital outputs of PiXtend eIO Digital One
devices. But a separate protection for the suppl of the outputs is a legitimate wa .
In an case, the suppl connections of the outputs to the suppl and a GND line are
connected.
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Figure 1: Topology o the power supply
PiXtend eIO Hardware Manual
If the modules are spatiall separated in a network or it is necessar to use several power
supplies for the entiret of the bus participants for other reasons, the ground (GND) of all
power supplies must be connected to each other at a central ground point via a suitable
cable - equipotential bonding.
In the following figure 2 we show ou t pical wiring errors with regard to the power suppl
of the modules.
At first glance, it ma make sense to "bridge" / "looping" the suppl voltage and GND from
one module to the next. However, this leads to voltage drops on the lines, especiall when
using small conductor cross-sections and man devices. The result ma be that the
required minimum voltage is no longer applied to a part of the modules and the devices do
not or no longer full fulfill their function.
A particularl serious error occurs when the GND line is "saved" at the suppl connection.
One could come up with this idea, since alread at the RS485 connections a GND
connection is made. However, the suppl current of the modules must under no
circumstances be routed via this connection.
Transmission errors, incomprehensible communication behavior and possibl overloading,
usuall thin bus lines, can be caused b this.
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Figure 2: Topology o the power supply - typical errors
PiXtend eIO Hardware Manual
Similarl , the potential equalization between several power supplies (GND connection
between all power supplies, which suppl devices on the bus) must not be omitted!
Summar :
•Make the conductor cross section for the suppl connections larger in case of doubt
(we recommend 0.75 or 1.00 mm²)
•Separate wiring of each module from the suppl point / ground point
•Suppl of the digital outputs also with two lines and provided with external fuse (see
also page 94 and following)
•Connect GNDs of all power supplies together (central ground point)
•Separate GND line for suppl - independent of the RS485 lines
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3.2. Bus Topology & Wiring
The PiXtend eIO devices communicate via a 2-wire1 RS485 network. This must be done
as a line structure / bus structure. The topolog (see Fig. 3) must be adhered to in order to
ensure error-free bus operation - even over longer transmission distances and baud rates.
In order to be able to implement the bus structure in the best possible wa , PiXtend eIO
devices offer each of the RS485 signals twice on terminal blocks. This reduces the so-
called "stub lines" to a minimum and enables high transmission rates.
The recommended structure of the RS485 network with PiXtend eIO (slaves) and PiXtend
V2 -L- (master) is shown in the following figure:
At the beginning and at the end of the bus structure, a terminating resistor is activated.
This bus structure is no longer so widespread toda . Usuall , networks are built as a star
(example: Ethernet with RJ45 connectors & switches / hubs). A star could also be
produced with RS485, but this should be avoided! These and other t pical wiring errors
are shown in Figure 4.
1 or 3-wire, if GND is carried along - as it is prescribed for Modbus, for example
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Figure 3: Bus topology – RS485
PiXtend eIO Hardware Manual
There are different topologies for networks. However, star, tree, ring and mesh networks
are not suitable for RS485 and therefore not for PiXtend eIO.
RS485 is alwa s set up as a line or in a bus structure.
All participants within a PiXtend eIO network need the same ground reference. Without a
common ground, there can be transmission problems and, in the worst case, a defect in
the RS485 drivers. In case of doubt, please contact PiXtend support via email with the
most accurate description, sketch and wiring diagram possible at [email protected],
even before such problems arise.
The GND connection (GND / C) of the RS485 interface is not suitable for such
equipotential bonding. Cables on these connections are onl used to increase the
immunit to interference and are optional (not optional for Modbus). Compensation
currents, as an example between different plant components in the industr , must never be
routed via the GND / C connections of the RS485 interface. Exactl so these connections
are also not intended or suitable as a shield connector of cables.
Another common mistake has to do with the termination resistors (termination). Either no
terminators are used or the are in the wrong place on the network. Also, too man (more
than two) termination resistors adversel affect data transfer. Correctl , two resistors are
120 Ω - one at each end of the line structure.
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Figure 4: Bus topology – RS485 – typical mistakes
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