Sferalabs Iono RP D16 User manual

Iono RP D16 User Guide
August 2022
Revision 001
IRMD10X Iono RP D16
IRMD10R Iono RP D16 with RTC
IRMD10S Iono RP D16 with RTC and Secure Element
a general-purpose, industrial input/output module based on the Raspberry Pi RP2040
!

Safety information 4
Qualified personnel 4
Hazard levels 4
Safety instructions 5
General safety instructions 5
Battery 5
Introduction 7
Features 8
Usage and connections 9
Device identification 9
Power supply 10
Control logic section 10
Digital input/output section 10
Auxiliary voltage outputs 10
D1-D16 digital inputs 10
D1-D16 digital outputs 11
D1-D16 connection and protection 11
Overvoltage protection 12
Thermal protection 12
DT1-DT4 5 V-level input/output lines 12
RS-485 serial port 12
EERAM 14
ON LED control 14
Mapping 15
Hardware Installation 16
Opening the case 16
Closing the case 16
Software development 18
Programming interfaces 18
USB interface 18
SWD interface 19
Optional components 20
Real Time Clock module 20
Replacing the RTC backup battery 20
ATECC608 secure element 21
Earthquake sensor module 22
1
Iono RP D16 User Guide

Block diagram 23
Board layout 24
Technical specifications 25
Dimensions 28
Disposal 29
Installation and use restrictions 29
Standards and regulations 29
Safety instructions 29
Set-up 29
Conformity Information 30
EU 30
USA 30
CANADA 30
RCM AUSTRALIA / NEW ZEALAND 31
2
Iono RP D16 User Guide

Iono RP D16 must be operated with the plastic case installed.
Follow all applicable electrical safety standards, guidelines,
specifications and regulations for installation, wiring and operations of
Iono RP D16 modules.
Carefully and fully read this Iono RP D16 user guide before installation.
Iono RP D16 is not authorised for use in safety-critical applications where a failure of the
product would reasonably be expected to cause personal injury or death. Safety-critical
applications include, without limitation, life support devices and systems, equipment or
systems for the operation of nuclear facilities and weapons systems. Iono RP D16 is
neither designed nor intended for use in military or aerospace applications or
environments and for automotive applications. Customer acknowledges and agrees that
any such use of Iono RP D16 is solely at Customer's risk, and that Customer is solely
responsible for compliance with all legal and regulatory requirements in connection with
such use.
Sfera Labs S.r.l. may make changes to specifications and product descriptions at any time,
without notice. The product information on the web site or materials is subject to change
without notice.
Please download and read the Sfera Labs Terms and Conditions document available at:
http://www.sferalabs.cc
Iono and Sfera Labs are trademarks of Sfera Labs S.r.l. Other brands and names may be
claimed as the property of others.
"
Copyright © 2022 Sfera Labs S.r.l. All rights reserved.
3
Iono RP D16 User Guide

Safety information
Carefully and fully read this user guide before installation and retain it for future reference.
Qualified personnel
The product described in this manual must be operated only by personnel qualified for the
specific task and installation environment, in accordance with all relevant documentation
and safety instructions. A qualified person should be capable of fully identifying all
installation and operation risks and avoid potential hazards when working with this product.
Hazard levels
This manual contains information you must observe to ensure your personal safety and
prevent damage to property. Safety information in this manual are highlighted by the safety
symbols below, graded according to the degree of danger.
Indicates a hazardous situation which, if not avoided, will result in death or serious
personal injury.
Indicates a hazardous situation which, if not avoided, may result in death or serious
personal injury.
Indicates a hazardous situation which, if not avoided, can result in minor or moderate
personal injury.
Indicates a situation which, if not avoided, can result in damage of property.
DANGER
WARNING
CAUTION
NOTICE
4
Iono RP D16 User Guide

Safety instructions
General safety instructions
Protect the unit against moisture, dirt and any kind of damage during transport, storage
and operation. Do not operate the unit outside the specified technical data.
Never open the housing. If not otherwise specified, install in closed housing (e.g.
distribution cabinet). Earth the unit at the terminals provided, if existing, for this purpose.
Do not obstruct cooling of the unit. Keep out of the reach of children.
Life threatening voltages are present within and around an open control cabinet.
When installing this product in a control cabinet or any other areas where dangerous
voltages are present, always switch off the power supply to the cabinet or equipment.
Risk of fire if not installed and operated properly.
Follow all applicable electrical safety standards, guidelines, specifications and regulations
for installation, wiring and operations of this product.
Ensure that the product is properly installed and ventilated to prevent overheat.
The connection of expansion devices to this product may damage the product and other
connected systems, and may violate safety rules and regulations regarding radio
interference and electromagnetic compatibility.
Use only appropriate tools when installing this product. Using excessive force with tools
may damage the product, alter its characteristics or degrade its safety.
Battery
This product optionally uses a small lithium non-rechargeable battery to power its internal
real time clock (RTC).
WARNING
WARNING
NOTICE
5
Iono RP D16 User Guide

Improper handling of lithium batteries can result in an explosion of the batteries and/or
release of harmful substances.
Worn-out or defective batteries can compromise the function of this product.
Replace the RTC lithium battery before it is completely discharged. The lithium battery
must be replaced only with an identical battery. See the "Replacing the RTC backup
battery" section for instructions.
Do not throw lithium batteries into fire, do not solder on the cell body, do not recharge, do
not open, do not short-circuit, do not reverse polarity, do not heat above 100°C and protect
from direct sunlight, moisture and condensation.
Dispose of used batteries according to local regulations and the battery manufacturer's
instructions.
WARNING
6
Iono RP D16 User Guide

Introduction
Iono RP D16 combines the ease of use of the Raspberry Pi RP2040 microcontroller with
multiple digital input and output interfaces; the result is a rugged, safe, reliable and easy to
connect module, suited for installation both in industrial and residential environments.
Iono RP D16 has an embedded RP2040, with a dual-core Arm Cortex M0+ processor,
clocked up to 133 MHz, 264#KB of SRAM, and a large 16#MB on-board Flash memory.
A hidden USB 1.1 port with device and host support is primarily used to easily flash the
microcontroller, but could also be used to connect external USB devices.
7
Iono RP D16 User Guide

Features
The Iono RP D16 key features are:
✓12÷28#Vdc power supply, with surge and reverse polarity protection, and 1.1#A
resettable fuse
✓RP2040, dual-core Arm Cortex M0+ processor, clocked up to 133 MHz, 264#KB of
SRAM
✓16#MB on-board Flash memory
✓16 isolated digital input/output lines, with dedicated power supply inputs
✓current-sinking 24#V IEC 61131-2 compliant industrial digital inputs with diagnostics,
based on MAX22190
✓640#mA, 24#V outputs that can be configured as high-side switches or push-pull drivers
for high-speed switching, based on MAX14912/MAX14913
✓four 5#V level digital input/output lines
✓standard RS-485 interface to the RP2040 UART serial pins, with electrostatic discharge
protection
✓1-Wire, I2C and Wiegand support
✓auxiliary 5#V and supply voltage outputs, with overcurrent protection
✓optional real time clock with on-board Lithium / Manganese Dioxide back-up battery
✓optional secure element chip
✓optional earthquake sensor module
✓removable terminal blocks for easier installation
✓inputs protected against electrostatic discharges and temporary over voltages
✓compact, standard modular housing 3 units size, suitable for mounting on Omega rail.
8
Iono RP D16 User Guide

Usage and connections
CONNECTION EXAMPLE
Device identification
The device can be identified with the information provided in the rating and identification
plate, permanently attached to the side of the case.
EXAMPLE RATING AND IDENTIFICATION PLATE
9
Iono RP D16 User Guide

Power supply
Iono RP D16 can be powered with DC voltage only.
The device is split in two distinct and galvanically isolated sections, the control logic
section and the digital input/output section.
Control logic section
✓DC: nominal voltage between 12#V and 28#V (min=10#V, max=30#V)
Respect the correct polarity shown in the schematic diagram (+ -). The power supply
circuit implements reverse polarity protection using an auto resetting fuse and surge
protection up to ±500#V/2#Ohm 1.2/50#μs.
Digital input/output section
✓DC: nominal voltage between 12#V and 28#V (min=10.5#V, max=36#V)
Respect the correct polarity: ground connected to IGND and positive voltage level to IVINL
and IVINH. IVINL and IVINH can be supplied with different voltages.
IVINL powers the D1-D8 outputs, while IVINH separately powers the D9-D16 outputs.
IVINL and IVINH are not required for the inputs. If all D1-D8 lines are used as inputs, IVINL
should be left unconnected. If all D9-D16 lines are used as inputs, IVINH should be left
unconnected. The IGND connection is always required.
IGND, IVINL and IVINH are each available at two adjacent terminals on the terminal
blocks. Always connect both terminals to the appropriate lines, as a significant amount of
current may flow through these lines.
Auxiliary voltage outputs
Iono RP D16 has an auxiliary 5#Vdc voltage output pin on the terminal block, labeled
5VOUT, to supply power to external 1-Wire devices or other low-power loads. This output
implements an overcurrent protection circuit, with a typical maximum current of 420#mA.
When 5VOUT is turned off because the overcurrent threshold has been exceeded, it is
automatically turned back on when the load is removed.
Another auxiliary voltage output pin, labeled VSOUT, is also available on the terminal
block. It is intended as the voltage source for small loads and dry contacts connected to
the digital inputs. Its typical output voltage is VS - 1#V. Do not exceed the maximum rated
current of 300#mA on this output.
D1-D16 digital inputs
Iono RP D16 has two banks of current-sinking 24#V IEC 61131-2 compliant industrial
digital inputs, based on two MAX22190 integrated circuits, connected to D1-D8 and D9-
D16 terminals. Wire-break detection can be enabled individually on each input line.
The MAX22190 chips are controlled by the RP2040 via its SPI serial bus, chip-select lines,
a latch line and a shared fault line.
All these control lines are galvanically isolated from the RP2040 logic section.
10
Iono RP D16 User Guide

The latch line can be used to synchronize input data on both input banks.
The fault line is asserted (low) on various, configurable, fault conditions, including wire-
break.
Refer to the MAX22190 data sheet for the complete specifications of the digital input lines.
D1-D16 digital outputs
Iono RP D16 has two banks of 24#V outputs that can be configured as high-side switches
or push-pull drivers for high-speed switching, based on two MAX14912/MAX14913
integrated circuits, connected to D1-D8 and D9-D16 terminals. Open-load detection in
high-side mode detects open-wire conditions in the switch on/off states. Internal active
clamps accelerate the shutdown of inductive loads in high-side mode. Other diagnostic
and protection features include per chip and individual line thermal shutdown, overvoltage
detection, and overcurrent detection.
The MAX14912/MAX14913 chips are controlled by the RP2040 via its SPI serial bus, chip-
select lines, a watchdog enable line, and a shared fault line.
The watchdog enable line is pulled high (enabled), so that the MAX14912/MAX14913
watchdog logic is normally active. It can be driven low by the RP2040 to disable the
watchdog if needed.
The fault line is asserted (low) on various fault conditions, including open-load.
All these control lines are galvanically isolated from the RP2040 logic section.
Refer to the MAX14912/MAX14913 data sheet for the complete specifications of the digital
output lines.
D1-D16 connection and protection
Besides the diagnostics and protection mechanisms implemented in the MAX14912/
MAX14913 output drivers, additional protections should be implemented in the RP2040 to
prevent overheating and permanent damage in specific conditions. Two of these
conditions are discussed below.
These protection mechanisms are implemented in the standard libraries provided by Sfera
Labs (see the "Software development" chapter). If the user's firmware does not use the
provided libraries, it shall implement the protection logic described below.
Some use cases may require the implementation of different or additional protection logic,
or be subject to other electrical and operational limitations.
If the IVINL lines are connected, never apply voltages higher than IVINL to the D1-D8
lines.
If the IVINH lines are connected, never apply voltages higher than IVINH to the D9-D16
lines.
WARNING
11
Iono RP D16 User Guide

Overvoltage protection
When an output line of the MAX14912/MAX14913 driver is configured as high-side and set
to OFF, if a voltage is applied to that line that is higher than 0.3V + IVIN , a considerable
1
amount of current will flow from the output to the MAX14912/MAX14913 VDD, and to the
IVIN terminal, if IVIN is connected.
The MAX14912/MAX14913 will heat quickly, possibly leading to permanent damage of the
chip itself and the device in general.
Setting the output to ON will still allow current to flow from out to IVIN, but the internal
resistance becomes very low, reducing the IC's dissipation and temperature.
When this condition occurs, the per-channel overvoltage bits in register 7 are set to 1. This
can be used to protect the IC. The firmware should check register 7 and, if an OV flag is
set, the corresponding output should be driven to ON and remain in this state for at least
10#seconds.
This logic should also be implemented when a D1-D16 line is configured as an input (and
thus the output is set to high-side/OFF and never driven ON).
Connecting only passive loads to the D1-D16 lines, when used as outputs, or dry contacts
powered by IVIN, when used as inputs, electrically prevents the occurrence of an
overvoltage condition.
Thermal protection
If the MAX14912/MAX14913 per-channel thermal shutdown occurs, with THSD bits in
register 5 being set to 1 for the affected outputs, the firmware should configure the output
as high-side/OFF for at least 30 seconds, before returning to the original configuration.
DT1-DT4 5!V-level input/output lines
Iono RP D16 features 4 general-purpose TTL-level (0-5#V) input/output lines, that can also
be used as 1-Wire, I2C, or Wiegand interfaces."
You should limit the voltage applied to the DT1-DT4 between +0#V and +5#V (TTL level).
Exceeding this voltage range will result in damage to the RP2040 board and Iono RP D16.
RS-485 serial port
Iono RP D16 uses the RP2040 UART0 TX/RX pins (GPIO16 and GPIO17 respectively) to
implement a standard RS-485 serial port.
Simply connect the RS-485 A, B, and GND to the RS-485 pins of the terminal block.
The RS-485 port is protected from ESD and voltage surges, and supports half-duplex
communication up to to 115200 bps.
NOTICE
IVINL for D1-D8 and IVINH for D9-D16.
1
12
Iono RP D16 User Guide

The RS-485 TX/RX switching is controlled by a digital output pin of the RP2040 (GPIO14).
You should set GPIO14 low to enable transmission on the RS-485, and set it high to allow
reception of incoming data.
If GPIO14 is left high, or not configured as output during transmission, the Iono RP D16
RS-485 driver will automatically drive the RS-485 lines in the dominant state, so that it is
not strictly required to control GPIO14 in order to transmit data.
The RS-485 line has 620 Ohm pull-up and pull-down resistors on lines A and B. The
biasing resistors ensure that, during idle periods the data lines are kept at a stable voltage
level and prevent false triggering of receiver input. A 120 Ohm termination resistor
between A and B can also be enabled.
RS-485 JUMPERS SCHEMATIC
These resistors can be enabled installing jumpers on JP1 according to the following table.
"
RS-485 JUMPERS POSITION
A PULL-UP
B PULL-DOWN
TERMNATION
13
Iono RP D16 User Guide

EERAM
Iono RP D16 has a Microchip 47L16 16 Kbit SRAM with EEPROM Backup. This chip
combines the persistent storage characteristics of a traditional EEPROM, without the
limitations in terms of number of erase cycles. It is connected to the RP2040 I2C bus I2C0,
GPIO0 (SDA) and GPIO1 (SCL), address: 0x50 for the SRAM and 0x18 for the control
register.
ON LED control
The ON LED is normally on when the Iono RP D16 is powered, but it is also possible to
control it from the RP2040 using the SPI CS (chip select) lines, as shown in the circuit
diagram below. To turn the LED on or off, first set the SPI CS OUT D1-D8 line low or high,
then set both SPI CS IN D1-D8 and SPI CS IN D9-D16 low to latch the LED status. The
LED will remain in its on or off state until SPI CS IN D1-D8 and SPI CS IN D9-D16 are
again both set low to latch a new state.
ON LED CONTROL LINES
14
Iono RP D16 User Guide

Mapping
The following table shows the mapping of the inputs and outputs of the Iono RP D16
module to the related pins of the RP2040 microcontroller.
Iono RP D16 inputs and outputs
RP2040 pins
DT1
38 (GPIO26)
DT2
39 (GPIO27)
DT3
40 (GPIO28)
DT4
41 (GPIO29)
SPI CLOCK
4 (GPIO2)
SPI MOSI
5 (GPIO3)
SPI MISO
6 (GPIO4)
SPI CS OUT D1-D8 (active low)
8 (GPIO6)
SPI CS OUT D9-D16 (active low)
7 (GPIO5)
SPI CS IN D1-D8 (active low)
11 (GPIO8)
SPI CS IN D9-D16 (active low)
9 (GPIO7)
IN LATCH D1-D16 (active low)
12 (GPIO9)
OUT WD ENABLE
29 (GPIO18)
IN FAULT D1-D16 (active low)
30 (GPIO19)
OUT FAULT D1-D16 (active low)
31 (GPIO20)
RS-485 RX
28 (GPIO17)
RS-485 TX
27 (GPIO16)
RS-485 TX-ENABLE (active low)
17 (GPIO14)
I2C SDA for EERAM and optionals
2 (GPIO0)
I2C SCL for EERAM and optionals
3 (GPIO1)
15
Iono RP D16 User Guide

Hardware Installation
For the initial set-up, the plastic DIN rail case must be removed to access the circuit
boards and internal connectors, including the USB connector and the BOOTSEL button.
The case also needs to be opened to change the factory configuration of the internal
jumpers for the RS-485 termination resistors.
Before opening the Iono RP D16 case, disconnect all power sources and any connection
to external devices.
Opening the case
Follow these steps, in the exact order, to open the case:
1. Remove the green pluggable terminal blocks
2. Remove the black plastic DIN rail hook
3. With a small flat screwdriver gently separate the bottom case and boards assembly
from the top cover
4. The circuit boards assembly will simply slide out of the case, as it is mechanically held
in place by the bottom case only
Closing the case
5. Replace the circuit boards assembly inside the case; ensure that the terminal block
connectors are aligned with the opening in the case
6. Replace the case bottom, then gently push the other side in place
7. Replace the black plastic DIN rail hook.
OPENING AND CLOSING THE CASE
NOTICE
16
Iono RP D16 User Guide

Static electricity can damage the components in your system. To protect your system's
components from static damage during the installation process, touch any of the unpainted
metal surfaces on your computer's frame or wear an ESD wrist strap before handling
internal components. Either method will safely discharge static electricity that's naturally
present in your body.
When handling the Iono RP D16 circuit boards, be sure to hold them along the side edges
using your thumb and index finger. Avoid touching the components and pin connectors as
damage may occur.
NOTICE
17
Iono RP D16 User Guide

Software development
Programming Iono RP D16 is as simple as any other RP2040-based boards, like the
original Raspberry Pi Pico board.
You can program it in C/C++, MicroPython, or any other supported derived languages,
using any IDE or tool available for the RP2040 microcontroller or Pico board.
Refer to the following link for an overview on how to get started with RP2040
programming:
https://www.raspberrypi.org/documentation/rp2040/getting-started/
"
For resources specific to Iono RP D16, go to:
https://github.com/sfera-labs/iono-rp-d16
The provided libraries implement various utilities as well as protection logic to prevent
damage during hazard conditions. Moreover, examples and ready-to-use applications are
included.
Programming interfaces
Iono RP D16 features the same programming interfaces of the Pico board: USB and SWD.
USB interface
The simplest way to program Iono RP D16 is by connecting it to a computer via USB, then
dragging and dropping a program file onto it or using your IDE's features.
To set Iono RP D16 to BOOTSEL mode and have your computer see it as a USB Mass
Storage Device:
• Remove power to Iono RP D16 and make sure the USB is unplugged;
• Push and hold the BOOTSEL button and connect the USB cable from your computer;
• Release the BOOTSEL button after Iono RP D16 is connected;
• It will mount as a Mass Storage Device called RPI-RP2.
BOOTSEL BUTTON AND USB CONNECTION
18
Iono RP D16 User Guide

Programming Iono RP D16 via USB does not require it to be connected to a power supply,
but when powered only though USB most of Iono's I/O will not be functional."
SWD interface
Serial Wire Debug (SWD) is a standard interface on Cortex-M-based microcontrollers,
which the host computer can use to reset the board, load code into flash, set the code
running, and interactively debug it.
Iono RP D16 exposes the RP2040 SWD interface on the CN1 header:
SWD INTERFACE
where the top pin (next to the CN1 marking) is the SWCLK line, the center pin is GND and
the bottom pin is the SWDIO line.
When using the SWD interface Iono RP D16 needs to be connected to a power supply or
powered via USB. You can use a standard debug probe, the GPIOs of a Raspberry Pi or a
Pico board to connect to the SWD interface.
For more details, refer to chapter 5 and 6 of the "Getting started with Raspberry Pi Pico"
guide:
https://datasheets.raspberrypi.org/pico/getting-started-with-pico.pdf
19
Iono RP D16 User Guide