Sferalabs Iono Pi Max Series User manual

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Iono Pi Max User Guide
September 2020
Revision 003
ICMX10XS Iono Pi Max Solo
ICMX10XPL Iono Pi Max 3+ Lite
ICMX10XP1 Iono Pi Max 3+ 8GB
ICMX10XP2 Iono Pi Max 3+ 16GB
ICMX10XP3 Iono Pi Max 3+ 32GB
!

Safety information 6
Qualified personnel 6
Hazard levels 6
Safety instructions 7
General safety instructions 7
Battery 8
Introduction 9
Features 10
Hardware setup 12
Device identification 12
Connections 12
Opening the case 13
Closing the case 13
Raspberry Pi Compute Module installation 14
How to flash the eMMC 14
microSD installation 14
The external UPS battery 15
Replacing the RTC backup battery 16
Terminal blocks 18
Power supply 19
Battery charger 20
Auxiliary voltage outputs 20
PWR LED status 20
Software installation and configuration 21
Raspberry Pi OS Kernel module 21
Raspberry Pi OS Real Time Clock installation 21
Raspberry Pi OS SocketCAN driver 22
Alternative set-up 23
Using Iono Pi Max 24
Real Time Clock 24
RS-232 serial port 24
RS-485 serial port 24
CAN FD port 26
EXP port 27
SD matrix 28
USB ports power management 30
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Iono Pi Max User Guide

ATECC608A secure element 31
EERAM 32
Push button 32
LEDs 32
Power supply 33
Shutdown enable mode 33
Shutdown wait time 34
Power-off time 34
Power-up delay 34
Power-up mode 34
UPS and battery charger 34
Auxiliary voltage outputs 35
Hardware watchdog 35
Internal fan and temperature sensors 36
Analog inputs 36
AVx: Analog voltage inputs 37
AIx: Analog current inputs 37
ATx: Temperature sensors inputs 38
AOx: Analog voltage and current outputs 38
DIx: Digital inputs 38
OCx: Open collector outputs 38
DTx: Digital input/output (Wiegand, 1-Wire) 39
Ox: Relays 40
Earthquake sensor module 40
Advanced usage 41
Dedicated GPIO pins 41
Raspberry Pi I2C bus addresses 42
I2C Configuration and control registers map 43
Firmware upload and MCU programming 57
Thermal considerations for Iono Pi 60
Block diagram 62
Technical specifications 66
Dimensions 71
Disposal 72
Installation and use restrictions 72
Standards and regulations 72
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Safety instructions 72
Set-up 72
Conformity Information 73
EU 73
USA 73
CANADA 74
RCM AUSTRALIA / NEW ZEALAND 74
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Iono Pi Max User Guide

Be sure to always remove the power supply before inserting or
removing the Raspberry Pi Compute Module from the Iono Pi Max.
Follow all applicable electrical safety standards, guidelines,
specifications and regulations for installation, wiring and operations of
Iono Pi Max.
Carefully and fully read this Iono Pi Max user guide before installation.
Iono Pi Max 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 Pi Max is neither
designed nor intended for use in critical military or aerospace applications or environments
and for automotive applications or environment. Customer acknowledges and agrees that
any such use of Iono Pi Max 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 © 2020 Sfera Labs S.r.l. All rights reserved.
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Iono Pi Max 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
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Iono Pi Max 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.
The Raspberry Pi Compute Module board could generate a substantial amount of heat
when the software forces the CPU and/or GPU to operate at high load levels. Ensure that
the product is properly installed and ventilated to prevent overheat.
The Iono Pi Max internal power supply could generate a substantial amount oh heat,
particularly when subject to a significant amount of electrical load.
An internal fan significantly improves the airflow and heat dissipation. Depending on
external environment conditions, the fan could collect a significant amount of dust or other
impurities, that could prevent it from spinning or could reduce its effectiveness. Periodically
check that the fan is not blocked or partly obstructed.
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.
WARNING
WARNING
NOTICE
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Iono Pi Max User Guide

Battery
Iono Pi Max uses a small lithium non-rechargeable battery to power its internal real time
clock (RTC).
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
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Iono Pi Max User Guide

Introduction
Iono Pi Max is an extremely versatile industrial server with a huge variety of Input/Output
lines and standard communication interfaces, based on the Raspberry Pi Compute
Module, suitable for use in professional and industrial applications where reliability and
service continuity are key requirements, and housed in a compact 6 modules DIN rail
case.
Iono Pi Max can be used for an incredible range of applications, from data acquisition and
control, to home and building automation, as well as access control, hotel room control
solutions, environmental monitoring and many others.
It is available in several versions. Iono Pi Max 3+ ships with a Raspberry Pi Compute
Module 3+ (Lite, or 8GB, 16GB and 32GB eMMC versions) pre-installed, while Iono Pi
Max Solo doesn't include the Compute Module and is compatible with all current versions
of the Compute Module: 3, 3 Lite, 3+ and 3+ Lite.
The information contained in this manual covers both Iono Pi Max 3+ and Iono Pi Max
Solo. Besides the fact that Iono Pi Max 3+ has the Compute Module pre-installed, all
versions are otherwise identical.
This manual generally refers to all products as Iono Pi Max.
IONO PI MAX
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Iono Pi Max User Guide

Features
Iono Pi Max, all versions:
✓compatible with Raspberry Pi Compute Module 3, Raspberry Pi Compute Module 3
Lite, Raspberry Pi Compute Module 3+ 8GB, Raspberry Pi Compute Module 3+ 16GB,
Raspberry Pi Compute Module 3+ 32GB, Raspberry Pi Compute Module 3+ Lite
✓10-50Vdc power supply, with surge and reverse polarity protection, and 3.3A resettable
fuse
✓integrated uninterruptible power supply (UPS), with external lead-acid 12V or 24V
battery (with reverse polarity and over-current protection)
✓software-controlled auxiliary 12-24Vdc stabilised supply output, to power external
devices through Iono Pi Max UPS
✓software-controlled auxiliary 5Vdc stabilised supply output
✓voltage and current monitoring of power supply input, battery and auxiliary supply
output
✓real time clock with replaceable CR1220 Lithium / Manganese Dioxide back-up battery
✓standard RS-232 interface to the Raspberry Pi serial line, up to 115.200 bps
✓standard RS-485 interface, routed to the Raspberry Pi serial line or USB, with opto-
isolator and electrostatic discharge protection, up to 115.200 bps
✓Controller Area Network (CAN) V2.0B and CAN-FD interface, support speeds up to 8
Mb/s, with opto-isolator and electrostatic discharge protection
✓5V-level, protected, I2C expansion bus
✓4 power relay outputs rated for 6A at 250V, with NO and NC contacts
✓4 open-collector outputs
✓2 0-10V or 0-20mA analog outputs
✓4 analog voltage inputs 0-20V
✓4 analog current inputs 0-20mA
✓2 Pt100 or Pt1000 temperature sensor inputs
✓4 digital input lines
✓4 digital 5V-level I/O lines, with 1-Wire and Wiegand support
✓10/100 Ethernet port
✓two USB 2.0 type-A ports, with individual power control and fault detection
✓one internal USB 2.0 type-A port, to embed USB dongles inside the enclosure
✓dual microSD card architecture. Iono Pi Max routes its two microSD card holders to the
Compute Module through a high-speed switching matrix, controlled by the on-board
microcontroller. Each SD card can be set as the boot card, with the other available as
additional storage. This enables for separate OS/data storage, SD redundancy and in-
field full-system upgrades. The microSD slots are hidden, and can be accessed
opening the case
✓hardware watchdog implemented in the Iono Pi Max microcontroller, fully independent
from the Raspberry Pi Compute Module, controlled via the GPIO pins of the Raspberry
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Iono Pi Max User Guide

Pi board and acting on the Raspberry Pi Compute Module hardware reset line. The
hardware watchdog can also control the microSD switch matrix, swapping the boot
card in case the watchdog is triggered
✓powerful and user-programmable 32 bit microcontroller (ATSAME54), with 1 MB
program memory and 256 KB RAM. The microcontroller is interconnected to the
Raspberry Pi via I2C, USB and CAN. It can also take direct low-level control of all serial
ports and digital as well as analog I/O
✓integrated Serial Wire Debug (SWD) interface to the Iono Pi Max microcontroller,
allowing in-field firmware upgrades, but also development and debugging, directly from
the Raspberry Pi
✓embedded Microchip ATECC608A secure element chip
✓front-panel RGB LEDs for power supply and serial line activity, can also be directly
controlled by the Raspberry Pi
✓on-board piezoelectric buzzer, for acoustic feedback
✓front-panel push-button, connected to a GPIO pin
✓power supply, serial and I/O connections on pluggable terminal blocks
✓internal temperature sensors for system temperature monitoring
✓internal fan, controlled by the microcontroller based on current load and internal
temperature
✓packaged in a compact 6 modules DIN rail case
✓optional earthquake sensor module
Iono Pi Max 3+:
✓pre-installed and tested Raspberry Pi Compute Module 3+, Lite, 8GB, 16GB or 32GB
eMMC versions.
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Iono Pi Max User Guide

Hardware setup
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
Connections
IONO PI MAX CONNECTION EXAMPLE
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Iono Pi Max User Guide

For the initial set-up, the plastic DIN rail enclosure must be removed to access the circuit
boards and internal connectors, to install or remove the Raspberry Pi Compute Module
and the µSD cards.
The case also needs to be opened if the factory configuration of the RS-485 and CAN
termination resistors must be changed (see below), or to connect to the microcontroller
programming and debug header.
Before opening the Iono Pi Max enclosure, disconnect all power sources and any
connection to external devices, including USB and Ethernet cables.
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 case bottom and boards assembly
from the top shell; lift both sides gradually; pay attention not to touch the circuit boards
with the screwdriver's tip
4. The circuit boards assembly will simply slide out of the case, as it is mechanically held
in place by the case bottom only.
Closing the case
5. Remove the front panel. This will help aligning the circuit boards assembly with the
case walls
6. Replace the circuit boards assembly inside the case; ensure that the USB/Ethernet
connectors and terminal blocks are aligned with the openings in the case
7. Replace the case bottom, partially inserting both sides, then gently push on both sides.
The case bottom must perfectly fit and firmly hook to the case cover. If it doesn't, the
circuit boards assembly is not perfectly fit into the case top shell
8. Replace the front panel, ensuring that the frontal push-button is aligned to the panel's
hole
9. Replace the black plastic DIN rail hook.
NOTICE
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Iono Pi Max User Guide

OPENING AND CLOSING THE CASE
Raspberry Pi Compute Module installation
To install your own Compute Module in Iono Pi Max Solo, or replace the pre-installed
module, no tools are required once the plastic enclosure has been removed and the circuit
boards assembly is exposed. The Compute Module fits in a standard 200 pin DDR2
SODIMM (JEDEC MO-224 mechanical specification) slot.
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 Raspberry Pi Compute Module, be sure to hold it along the side edges
using your thumb and index finger. Avoid touching the components and pin connectors as
damage can occur.
Align the notches on the Compute Module with the ridges in the DDR2 slot. Insert the
module using firm and even pressure, and push down on the module until the clips on the
side of the slot snap into place.
How to flash the eMMC
The Compute Module versions 3 and 3+ have an on-board eMMC device connected to the
primary SD card interface.
In order to flash the Compute Module's eMMC memory, an additional board, like the
Compute Module IO Board V3, must be used.
microSD installation
Iono Pi Max has two microSD slots to install flash memory cards.
NOTICE
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Iono Pi Max User Guide

When the Compute Module Lite is installed, as it lacks an internal eMMC chip, one of the
two microSD slots will be used as the boot SD card, just like with a Raspberry Model B
board. The other microSD can be used as additional storage. Dedicated commands to the
microcontroller allow to select which slot is used for boot, and if the other is enabled or not.
When a Compute Module with embedded eMMC is installed, both microSD slots can be
used as additional storage. You can only access one SD card at a time, but the active card
can be selected sending the appropriate commands to the microcontroller.
The microSD slots are not directly accessible with the case closed. The slots are located
on the vertical board, next to the USB/Ethernet modular connector.
The bottom slot is SDA, and the top is SDB.
MICRO SD SLOTS
The external UPS battery
To take advantage of the UPS features of Iono Pi Max, you can connect an external lead
acid rechargeable battery to the BATT terminals. See the connection diagram above.
Improper handling of lead acid 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 battery every 5 years even if the battery is still working properly.
Only use a lead acid battery with electrical ratings recommended in the technical
specifications for this product (12V or 24V, 7Ah max).
Reversing the battery polarity may damage the product and the battery.
Dispose of used batteries according to local regulations and the battery manufacturer's
instructions.
WARNING
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Iono Pi Max User Guide

Follow the battery manufacturer's instructions when installing the external UPS battery (not
provided).
Replacing the RTC backup battery
Iono Pi Max has a hardware real time clock with a dedicated long-life non-rechargeable
back-up battery.
Iono Pi Max is shipped with a CR1220 Lithium / Manganese Dioxide (Li/MnO2) battery
1
installed.
The battery is only used to power the RTC chip when the main power is not available.
Depending on operating conditions it should last up to two years if the Iono Pi Max is not
powered, more if it regularly receives external power.
The RTC backup battery holder is on the vertical circuit board, opposite the Compute
Module slot. In the Iono Pi Max, the battery is not accessible from the outside. You should
first remove the case body to gain access to the Iono Pi Max circuit boards assembly.
Follow the procedure described at the beginning of this chapter to open and replace the
case.
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.
KEEP OUT OF REACH OF CHILDREN. Swallowing may lead to serious injury or death in
as little as 2 hours due to chemical burns and potential perforation of the esophagus.
Immediately see doctor.
Replace the RTC lithium battery before it is completely discharged. Replace the battery
every 5 years even if the battery is still working properly. The lithium battery must be
replaced only with an identical CR1220 or BR1220 battery.
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.
Before opening the Iono Pi Max enclosure, disconnect all power sources and any
connection to external devices, including USB cables.
WARNING
NOTICE
BR1220 batteries (Lithium Poly-carbonmonofluoride) can also be used, for improved shelf and
1
service life.
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Iono Pi Max User Guide

Once the circuit boards assembly is extracted from the enclosure, the most convenient
way to access the battery holder is to first separate the vertical board from the base board.
This is easily accomplished by unscrewing the two screws on the bottom side of the base
board, that secure the vertical board to it. Pay attention not to touch any of the electronic
components with the screwdriver head. Once the screws are removed, the vertical board
easily separates from the base. Be careful not to stress the board-to-board connector.
VERTICAL BOARD SCREWS
Use a non-conductive pin or small tool to help extract the battery from its holder. Insert the
new battery with a gentle push. You don't need tools to insert the battery. The battery is
held into place by a spring contact.
Be sure to insert the battery so that the negative (-) terminal is facing the vertical circuit
board, and touches the contact pad at the center of the battery holder, as shown in the
photo below. Reattach the vertical board to the base; use light torque to tighten the
screws.
Reversing the battery polarity may damage the product.
The real time clock will reset its time immediately when the RTC backup battery is
disconnected.
RTC BACKUP BATTERY HOLDER
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Iono Pi Max User Guide

RTC BACKUP BATTERY INSTALLED
Terminal blocks
Iono Pi Max has several pluggable terminal blocks.
All power supply, input/output and serial interfaces are on 3.81mm pitch terminal blocks.
The maximum conductor cross section is 1.31 mm2(16 AWG), or 0.5 mm2when using
ferrules (highly recommended). Recommended stripping length is 6 mm. Screw thread is
M2. Never exceed 0.3 Nm torque when tightening the screws.
Two 6 positions terminal blocks are dedicated to the power relays outputs.
The maximum conductor cross section is 3.31 mm2(12 AWG). Recommended stripping
length is 7 mm. Screw thread is M3. Never exceed 0.5 Nm torque when tightening the
screws.
THE IONO PI BOTTOM CIRCUIT BOARD WITH TERMINAL BLOCKS
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Iono Pi Max User Guide

THE IONO PI TOP CIRCUIT BOARD WITH TERMINAL BLOCKS
Power supply
Iono Pi Max can be powered with DC voltage only:
✓DC: nominal voltage range 10.0V to 50.0V.
Respect the correct polarity shown in the schematic diagram (+ -). The power supply
circuit implements reverse polarity protection using auto resetting fuses and surge
protection up to ±1000V (line to earth, common mode) 1.2/50μs. The resetting fuse
threshold is 3.3A at 20C ambient temperature.
The PWR color LED, visible through the front panel of the DIN-rail case, is lit when power
supply is available.
The Iono Pi Max power supply stage is optimised to deliver up to 30W total power through
its 5V main regulator. This regulator supplies all internal voltages, including the battery
charger voltage, but not the VSO (auxiliary regulated 12-24Vdc output) regulator voltage,
that draws directly from VIN or battery and can deliver up to 8W.
When the input voltage is below 24V, if the total power demand is very high from both the
main regulator and the VSO output, the input current threshold limit could be exceeded,
causing the resettable fuse to trip.
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Iono Pi Max User Guide

Battery charger
The Iono Pi Max UPS (uninterruptible power supply) implements a programmable battery
charger, that can charge an external lead-acid battery (other chemistries could be
supported with future firmware releases).
The battery line is protected by an internal 3.3A resettable fuse.
You can use either 12V or 24V batteries. The maximum battery capacity is 60Ah, but the
battery charger can deliver no more than approximately 600mA charging current, so
charging time for large batteries could be very long.
For low load applications, a 12V 1.2Ah battery is sufficient to keep Iono Pi Max running for
several minutes and perform an orderly shutdown. A 12V or 24V 7Ah battery is
recommended for high load applications.
The factory default configuration for the battery charger has the charger enabled and
configured for a 12V lead-acid battery with 800mAh capacity.
Ensure that the charger parameters are correctly configured before connecting the battery
to the battery terminals.
Auxiliary voltage outputs
Iono Pi Max has an auxiliary regulated voltage output, labeled VSO on the terminal block,
that can be set in a 12Vdc to 24Vdc voltage range, and is powered by the UPS. It can
deliver up to 8W, and its output is protected by a 1.1A resettable fuse.
Iono Pi Max also has an auxiliary 5Vdc voltage output pin on the terminal block, labeled
5VO, to supply power to external 5V loads, like 1-Wire devices. The current output limit is
500mA. An internal protection circuit shuts down the 5VO line if the current limit is
exceeded.
In the factory default configuration, both the 5VO and VSO outputs are enabled, with VSO
set for 12V output voltage.
PWR LED status
During normal operation, the PWR LED is stable green or stable blue (base color) to
indicate that the Raspberry Pi is using respectively SDA or SDB as boot SD card.
During power off time in a power cycle, the LED is stable red.
When the shutdown delay is running, a red blink is alternated with the base color.
When the watchdog timeout expires, a yellow blink is alternated with the base color.
When the module is running on battery power, the base color blinks on/off.
When system status warnings are active, a white blink is alternated with the base color.
In concurrent situations, priorities are given in the above order.
WARNING
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Iono Pi Max User Guide