Teracom TCG120-4 User manual

TCG120-4_R1.3 –May 2022 Page 2
1. Short description
TCG120-4 is a 4G LTE Cat.1 wireless I/O module. It supports also 3G and 2G wireless communication
and provides data connectivity on LTE-FDD, DC-HSDPA, HSPA+, HSDPA, HSUPA, WCDMA, EDGE, and
GPRS networks.
The device has 2 digital inputs, 2 analog inputs, 1-Wire interface for external sensors and 2 relays. The
relays can be activated either remotely (via SMS or HTTP API command) or locally - from the status of
the monitored parameters.
TCG120-4 supports all 1-Wire sensors of Teracom.
The universal I/O module supports HTTP API for easy M2M communication. The device sends
periodically an HTTP/HTTPS Post to a remote server with an XML/JSON status file. As an answer, the
server can send commands for relay activation or settings change.
2. Features
•Multi-band connectivity;
•Setup via USB, SMS, and HTTP API;
•2 digital "dry contact" inputs;
•2 analog inputs with 0 to 60VDC range;
•2 relays with NO and NC contacts;
•1-Wire support for all Teracom sensors;
•MQTT 3.1.1 support;
•SMS alarm alerts for up to 5 numbers;
•Email alarm alerts for up to 5 email recipients;
•Periodical HTTP/HTTPS Post with current status in XML or JSON file to a remote server;
•HTTP API commands;
•GSM geolocation;
•Firmware update over USB or Internet.
3. Applications
TCG120-4 is suitable for industrial automation, data acquisition systems, environmental monitoring,
local control of an electrical and non-electrical parameter, building automation, etc.:
•SCADA systems
TCG120-4 be easily integrated into SCADA systems. The periodical HTTP/HTTPS Post is
suitable for client-server platforms.
•Environmental monitoring and control
4. Specifications
•Physical characteristics
Dimensions: 109 x 65 x 32 mm
Weight: 152 g
Mounting: wall
•Environmental limits
Operating temperature: -20 to 55°C
Operating temperature for USB setup: 0 to 40°C
Storage temperature: -25 to 60°C

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Ambient Relative Humidity: 5 to 85% (non-condensing)
•Standards and Certifications
Safety: EN 62368-1:2014 + EN 62368-1:2014/AC1-3:2015 + EN 62368-1:2014/A11:2017 +
EN 62368-1:2014/AC:2017-03:2017, EN 62311:2008
EMC: EN 55032: 2015 + EN 55032: 2015/AC:2016-07 + EN 55032: 2015/A11:2020
EN 55024: 2010 + EN 55024: 2010/A1:2015
EN 61000-3-2: 2014
EN 61000-3-3: 2013 + EN 61000-3-3: 2013/A1:2019
RFU: EN 301 489-19 V2.1.1, EN 301511 V12.5.1, EN 301 908-1 V11.1.1,
EN 301 908-13 V11.1.2, EN 301 908-2 V11.1.2, EN 303 413 V1.1.1
Green: RoHS
•Warranty
Warranty period: 3 years
•Power supply
Operating voltage range (including -15/+20% according to IEC 62368-1): 10 to 28 VDC
Current consumption: 0.24A @ 12VDC
•Cellular interface
Standards: LTE-FDD, EDGE and GPRS
TCG120-4E (hv2) bands:
4G LTE: B1/B3/B5/B7/B8/B20
2G: B3/B8
SIM card size: Standard
Antenna connector: SMA-F
•Analog inputs
Isolation: Non-isolated
Type: Single-ended
Resolution: 10 bits
Input Range: 0 to 60 VDC
Accuracy: ±1%
Sampling Rate: 500ms per channel (averaged value of 250 samples)
Input Impedance: 1 mega-ohm (min.)
•Digital inputs
Isolation: Non-isolated
Type: Dry contact and logic level
Minimum high-level input voltage for digital inputs: +2.5VDC
Maximum low-level input voltage for digital inputs: +0.8VDC
Maximum input voltage for digital inputs: +5.5VDC
Sampling rate: 10ms
Digital filtering time period: 30ms
•Relay outputs
Type: Form C (N.O. and N.C. contacts)
Contact current rating: 3 A @ 24 VDC, 30 VAC (resistive load)

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Initial insulation resistance: 100 mega-ohms (min.) @ 500 VDC
Mechanical endurance: 10 000 000 operations
Electrical endurance: 100 000 operations @ 3 A resistive load
Contact resistance: 50 milli-ohms max. (initial value)
Minimum pulse output: 0.1 Hz at rated load
CAUTION: The device does not contain any internal overcurrent protection facilities on the
relays’ contact lines.
External fuses or short circuit current limiting circuit breakers, rated to 3 Amps, are to be
used for overcurrent protection of the connecting lines.
•1-Wire interface
Output voltage: 5.0 ± 0.3 VDC
Maximum output current: 200 mA
•Internal FLASH memory
•Endurance: 100 000 cycles (Every relay status and settings change is a memory cycle)
5. Installation
This device must be installed by qualified personnel. The installation consists of mounting the device,
connecting the antenna, connecting inputs and outputs, providing power, and configuring via a web
browser. This device must not be installed directly outdoors.
Attention! Before installing the SIM card in the card slot, please ensure that the PIN code is disabled.
5.1. Mounting
TCG120-4 should be mounted in a clean and dry location on a non-flammable surface. Ventilation is
recommended for installations where the ambient air temperature is expected to be high.
Mount the device to a wall by using two plastic dowels 8x60mm (example Würth GmbH 0912 802
002) and two dowel screws 6x70mm (example Würth GmbH 0157 06 70). See Appendix C, fig. 1 for
mechanical details.
Maintain spacing from adjacent equipment. Allow 50 mm of space on all sides, as shown in fig.2 in
Appendix C, this provides ventilation and electrical isolation.
5.2. Connectors
Attention! Disconnect the power supply before wiring.
The correct wiring procedure is as follows:
•Make sure power is turned off;
•Make wiring connections to the terminals;
•Apply power.
It is recommended to test and configure TCG120-4 without any controlled device.
Make sure that wires are properly attached to the terminals and that the terminals are tightened.
Not proper wiring and configuration can cause permanent damage to the module or the equipment
to which it is connected or both.
Inputs and outputs locations are shown below:

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Connector 1 –Power - 2.1x5.5mm
connector, central positive
Connector 2, Pin1 - Digital input 1 (Din1)*
Connector 2, Pin2 - Digital input 2 (Din2)*
Connector 2, Pin3 - Ground
Connector 2, Pin4 - Analog input 1 (Ain1)
Connector 2, Pin5 - Analog input 2 (Ain2)
Connector 2, Pin6 - Ground
Connector 2, Pin7 –1-Wire data
Connector 2, Pin8 –1-Wire power supply
Connector 3 –mini USB
Connector 4 –SIM card holder
Connector 5 –GSM Antenna
Connector 6, Pin1 –NC Relay2
Connector 6, Pin2 –COM Relay2
Connector 6, Pin3 –NO Relay2
Connector 7, Pin1 –NC Relay1
Connector 7, Pin2 –COM Relay1
Connector 7, Pin3 –NO Relay1
5.2.1. Power supply connection
TCG120-4 is designed to be supplied by adapter SYS1308-2412-W2E or similar, intended for use
in the conditions of overvoltage category II. The power supply equipment shall be resistant to
short circuits and overload in a secondary circuit.
When in use, do not position the equipment so that it is difficult to disconnect the device from
the power supply.
5.2.2. 1-Wire interface
1-Wire is a registered trademark of Maxim integrated products, Inc. It is designed to connect
several sensors over short wiring. It is not suitable for long distances or noisy environments.
The maximum number of 1-Wire sensors connected to TCG120-4 is four.
The device supports all Teracom 1-Wire sensors. Connected sensors are automatically detected
and the appropriate dimension is assigned.
It is strongly recommended to use “daisy-chained” (linear topology) for multi-sensor systems:

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“Star” topology can be used only as a last resort for up to 4 sensors and total cable length up to
10 meters:
It is strongly recommended to use only UTP/FTP cables and keep the total cable length up to
30m. Although functionality has been achieved in the longer distance, we cannot guarantee
error-free operation over mentioned wiring length. We recommend reading Maxim’s 1-Wire tips
at https://www.maximintegrated.com/en/design/technical-documents/tutorials/1/148.html.
We guarantee proper operation only with Teracom 1-Wire sensors.
5.2.3. Digital inputs connection
Attention! Digital inputs are NOT galvanic isolated.
The TCG120-4 digital inputs can be used as “dry contact” only.
The term “dry contact” means that to this input can be connected devices with an open drain or
relay outputs - door contact switch, push-button, PIR detector, etc.

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The following picture illustrates how an alarm button can be connected to a digital input of
TCG120-4. One side of the contact is connected to “Digital In” while the other side is connected
to the “GND” terminal.
The maximum cable length for a digital input should be up to 30 meters.
5.2.4. Analog inputs connection
Attention! Analog inputs are NOT galvanic isolated.
Analog inputs of TCG120-4 can be used for monitoring DC voltage up to 60VDC. They can be
connected directly to batteries, solar panels, power supplies etc.
The “Multiplier”, “Offset” and “Dimension” for every analog input gives a possibility to monitor
sensors with analog outputs and see directly the measured parameter.
5.2.5. Relays connection
The relay contacts are internally connected directly to the terminal connectors.
Attention! There isn’t any internal overcurrent protection on the relays’ contact lines.
For all relays normally open, normally closed and common contacts are available. For loads with
higher switchable current/voltage than specified, an external relay should be used.

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When mechanical relays switch inductive loads such as motors, transformers, relays, etc., the
current will arc across the relay contacts each time the contacts open. Over time, this cause
wears on the relay contacts which shorten their life. When switching an inductive load, it is
recommended that relay contact protection devices are used.
6. LED indicators
LED indicators show the status of the module:
•REL1 –REL2 (green) –the LED is ON when the corresponding relay is activated (the NO
contact is connected to COM);
•SIG (red) –indicates the status of the device together with STA
•STA (yellow) –indicates the status of the device together with SIG.
The following states are displayed:
•Module initialization –after power-on SIG and STA turn ON for a second, after this turn
OFF for another second.
•Searching for a network –after initialization, SIG is OFF, STA flashes (flash period of
200ms)
•Connected to a network –after a successful connection to a mobile network, STA shows
the type of connection, while SIG shows the signal strength.
STA flashes ones for 200ms in a period of 2s –there is GSM connection only;

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STA flashes twice for 200mS in a period of 2s –there are GSM and 4G/3G/2G connections.
At the same time SIG has 5 states:
SIG flashes 1 time in a period of 2s –signal strength is between 0 and 20%;
SIG flashes 2 times in a period of 2s –signal strength is between 21 and 40%;
SIG flashes 3 times in a period of 2s –signal strength is between 41 and 60 %;
SIG flashes 4 times in a period of 2s –signal strength is between 61 and 80%;
SIG is solid ON –signal strength is between 81 and 100%;
•Error message –in case of error after initialization, SIG will stay solid OFF, STA will flash
showing the type of error.
STA flashes ones for 1s –master phone number is not set;
STA flashes permanently for 1s in a period of 2s –permanent hardware error.
7. Initial setup via USB
The initial setup of TCG120-4 is done with a computer running Windows 7 or a newer Microsoft
Windows operating system. After power-up, the module should be connected to the computer with a
USB cable. Once the USB cable is connected, the operating system automatically starts to install the
drivers for the communication with the device. The following message appears:

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The following drivers will be installed:
-Microchip composite device
-USB serial port driver
If for some reason the USB serial port driver cannot be installed automatically, it must be installed
manually.
The driver can be downloaded from the TCG120-4 product page at www.teracomsystems.com. After
successful driver installation, the device will be recognized as Mass storage, the following window
appears on the screen:
The only file stored on the mass storage is a tool called “TConfig”. This tool enables communication
between the TCG120-4 and PC. After starting the TConfig tool, the following program will appear:
Pressing the “Start” button will start the browser and display the Monitoring page of your TCG120-4.

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7.1. Monitoring page
The monitoring page displays the current inputs/outputs status of TCG120-4.The page has 4
sections –“1-Wire sensors”, “Analog inputs”, “Digital inputs” and “Relays”.
For every parameter (sensor, input, relay) there is a description of up to 15 characters. The
descriptions can be changed on the “Setup-Input/Output” page.
7.1.1. Sensors section
TCG120-4 supports up to four sensors.
All detected 1-Wire sensors are shown in the “1-Wire sensors” section. The sensors should be set
up in section “1-Wire sensors setup” on the Setup->Sensors page.
For every sensor, there is a description, value, and ID information. The description length is up to
15 characters. The descriptions can be changed on the Setup->Conditions page.
Teracom temperature sensors readings are shown in the Value 1 column. TSH2xx temperature-
humidity sensors have the 2nd parameter shown on the Value 2 column.
7.1.2. Digital inputs section
Digital inputs can be used for monitoring the state of discrete devices –motion sensor, door
contact, relay contact, alarm output, etc.
Digital inputs are sampled every 10ms. The change of input status is considered valid if the same
value is read in 3 consecutive samples (30ms).
The status of every input is shown by text and by color.
The descriptions and status texts can be changed in “Setup-Input/Output”.

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7.1.3. Analog inputs section
Analog inputs can be used for monitoring DC voltage sources –analog sensors, batteries, power
supplies, solar panels, etc.
Analog inputs are sampled faster, but the new actual value is changed in 0.5 seconds. All 250
readings between the value changes are averaged.
For every analog input “Unit”, “Multiplier” and “Offset” can be set in the “Setup-> Input/Output”
section.
7.1.4. Relay section
The section displays the current state of relays. Each relay can be activated either remotely or
locally from the status of a monitored parameter. For locally activated relays a text describing
the controlling parameter is displayed rather than buttons.
Pulse duration and parameters for local relay activation can be set separately for each relay in
“Setup->Input/Output->Relay outputs”.
7.2. Setup
7.2.1. SMS
SMS alarm recipients can be set in this section.
The “Master” has special rights to change the device settings using SMS commands. By default,
this number receives SMS alarm messages. This can be changed by deactivation the alarm
notification checkbox.
“Master”will receive SMS for loss of internet connectivity if checkbox “Connectivity alert” is
activated. This checkbox is activated by default.

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The remaining 4 recipients can receive SMS messages if any of the parameters are in an alarm
state. To receive the SMS messages for every number should be enabled with the checkbox
“Alarm Notification”. These 4 recipients can also ask by SMS for parameter state/value.
Activating checkbox “Superuser rights” gives special rights to 4 users. Users can send all SMS
commands as the “Master”, except for commands to create new users and change the “Master”.
By pressing the “Send test SMS” button all SMS recipients will receive a test SMS.
All commands, their syntax, and answers are described in “Setup via SMS”.
SMS is not a reliable communication and it is not recommended as a monitoring technology.
7.2.2. 1-Wire sensors setup
Detection of connected 1-Wire sensors is made either after power on or by the button “Scan”.
All found sensors are shown in ascending order refer to their unique ID number.
It is possible to lock a 1-Wire sensor in a specific position. To do this all sensors should be
added one by one. After every addition, a new scan should be made and a newly found sensor
should be locked in its position. If all sensors are locked, removing one “in the middle” will not
change the positions of other sensors after reset. This option is very useful when TCG120-4 is
used as a part of а monitoring and control system managed by HTTP API commands.
7.2.3. Input/Output
7.2.3.1. Sensors
For every sensor, a description, up to 15 symbols can be set. These descriptions will appear in
the monitoring page, conditions page, XML/JSON data, SMS, and e-mail alerts.
For some sensors, fields “Unit”, “Multiplier” and “Offset” are available to convert the raw
values into meaningful units. The scaled value is calculated by:
SV[Un] = RV * MU + OF
Where:
SV –scaled (displayed) value;
Un –unit;
RV –raw value from the sensor;
MU –multiplier;
OF –offset.

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7.2.3.2. Digital inputs
For every digital input, a description, up to 15 symbols and states up to 15 symbols can be set.
These descriptions will appear in the monitoring page, conditions page, XML/JSON data, SMS,
and e-mail alerts.
7.2.3.3. Analog inputs
For every analog input, a description, up to 15 symbols can be set. These descriptions will
appear in the monitoring page, conditions page, XML/JSON data, SMS, and e-mail alerts.
For every analog input, fields “Unit”, “Multiplier” and “Offset” are available to convert the raw
voltage/current into meaningful engineering units. The scaled value is calculated by:
SV[Un] = RV * MU + OF
Where:
SV –scaled (displayed) value;
Un –unit;
RV –raw voltage from the source;
MU –multiplier;
OF –offset.
Example:
For humidity sensor HIH-4000-003 following data (from the datasheet) is available:
VOUT = 0.826 at 0% RH
VOUT = 3.198 at 75.3% RH
The raw values are voltages on the sensor’s output. Actually, we need to know relative
humidity (scaled value) not voltages. The two relations are enough to calculate multiplier

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and offset. When we know them, we can calculate what relative humidity corresponds to
every voltage in the working range.
The multiplier (MU) is calculated as ΔY/ΔX, for this sensor ΔRH%/ΔV:
MU = (75.3 - 0)/(3.198-0.826) = 75.3/2.372 = 31.745 %RH/V
The offset is calculated from the already known multiplier and relation for one of the
points:
OF = MU * (0 –VOUT1) + RH1 = 31.745*(0-0.826) + 0 = 31.745*(-0.826) = -26.22
The same result can be calculated for the second point:
OF = MU * (0 –VOUT2) + RH2 = 31.745*(0-3.198) + 75.3 = -101.52 + 75.3 = -26.22
For this sensor, the formula will look like this:
SV = RV * 31.745 –26.22
Check for VOUT = 0.826 V (0%RH):
SV = 0.826 * 31.745 –26.22 = 26.22 –26.22 = 0 %RH
The same value is written in the datasheet.
7.2.3.4. Relay outputs
For every relay, a description, up to 15 characters can be set. These descriptions will appear in
the monitoring page, XML/JSON data, SMS and e-mail alerts.
The pulse duration can be different for every relay. The resolution is 0.1 second, the maximum
pulse value is 3600 seconds.
All relays can be activated either remotely by SMS/HTTP API or locally from the status of a
monitored parameter. This setting is made from the “Activated from” drop-down menu, the
possible options are:
•SMS/HTTP - by selecting this option the relay outputs can be activated by SMS from
an authorized number or by sending HTTP API commands;
•Local activation.
For local activation, alarm conditions for different sources are used. They are set up in section
“Setup->Conditions”. To assign a parameter to the relay, the following choices are possible:
•S? –“S” stands for “Sensor 1-Wire”. The relay is activated from the value measured
from the specified 1-Wire sensor and rules for ranges specified in “Setup-
>Conditions”. Question mark masks a number from 1 to 4;
•Analog input?. The relay is activated from the value measured by specified analog
input and rules for ranges specified in “Setup->Conditions”. Question mark masks a
number from 1 to 2;
•Digital input?. The relay follows the state of the specified digital input. Question
mark masks a number from 1 to 2;
•Any alarm. The relay is activated on any alarm condition.
All changes in the above sections are saved by pressing the “Save” button.

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7.2.4. Conditions
This section is used for parameterization of trigger and alert conditions for sensors, analog, and
digital inputs.
7.2.4.1. Sensors and analog inputs
For every sensor two types of fields are presented –one for the trigger conditions (“Min”,
“Max”, and “Hys.”) and another one for the wanted action.
“Min” and “Max” indicate the border of the working range for the monitored parameter. The
“Max” trigger condition occurs when the value exceeds the trigger set point. The “Min” trigger
condition occurs when the value is lower than the trigger set point. In both cases, the
monitored parameter goes out of range.
Coming back in range for the observed parameter is considered when the value goes higher
than (Min + Hys) or lower than (Max –Hys). Hysteresis (“Hys”) is used to prevent excessively
triggering when the value fluctuates around the trigger point.

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Example:
TCG120-4, TST100, and an appropriate heater are used to control the room temperature. The
wanted minimum temperature is 19°C. The initial temperature is 17°C.
TST100 is assigned on the first position for 1-Wire sensors.
For Relay1 local activation from Sensor1 is set.
Following parameters are set for Sensor1: Min=19, Max=100 and Hys=0.5.
When the module is switched on, Relay1 is immediately activated because the monitored
temperature is out of range. This switches the heater on. The temperature is going higher.
When temperature reaches 19.5°C (19.0 + 0.5) it goes in range (trigger condition) and Relay1
is deactivated. The heater is switched off.
The temperature falls and when it reached 19°C it goes out of range (trigger and alert
conditions). The relay is activated (heater is switched on) and e-mail is sent.

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The “Max” value is set far enough from the wanted temperature to avoid trigger/alert
conditions around it.
For every sensor or analog input, there are 4 independent ways of alert when there is an
alarm condition –email, SMS, post (HTTP Post with XML/JSON file) and MQTT publish. Each
alarm notification method is activated by a checkbox.
Globally for all sensors and for all analog inputs, there is a checkbox “Return notification”. If
this option is chosen there will be a notification also when the parameter returns in range.
Globally for all sensors and for all analog inputs, there is a “Notification delay” parameter. It is
very useful as a filter for short alarm conditions.
7.2.4.2. Digital inputs
For every digital input, the alarm state should be chosen. The texts are already set on the
“Input/output” page.
When the input goes in alarm state 4 independent way of the alert are possible –email, SMS,
post (HTTP Post with XML/JSON file) and MQTT publish. Each alarm notification method is
activated by a checkbox.
Globally for all digital inputs, there is a checkbox “Return notification”. If this option is chosen
there will be a notification also when the parameter returns in range.
Globally for all digital inputs, there is a “Notification delay” parameter. It is useful as a filter for
short alarm conditions.

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In the time when the input is in an alarm state, on the „Monitoring page“, the appropriate
input will be colored in red.
There are two delays - low-to-high and high-to-low for digital input change. These delays are
added to the standard delay of 30ms. They have 0.1-second resolution and by default are
zero.
These options can be used for additional filtering.
On the picture above low-to-high and high-to-low delays are set to 0.1 seconds.
7.2.5. System
The page for some general settings.
7.2.5.1. System status
There is information about the general status of the module here.
The only possible setting here is the “Data in roaming” checkbox. By default, it is disabled to
avoid extra charges for data transfer in roaming.
If you are using another operator's card, you must activate “Data in roaming”. Otherwise, you
will not be able to use all data services –emails, HTTP Post, NTP, etc.

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7.2.5.2. Data connection setup
This setting can be different for each mobile operator. By default, APN (Access Point Name) is
“internet”. Some mobile operators may require also a username and password.
7.2.5.3. Mobile network connection reset
For areas with low signal strength or where the mobile network frequently drops/blocks,
automatic restarting of the network connection can be used. This could prevent permanently
losing the connection with the device.
The automatic restart will be done once per day.
By default, the automatic restart is disabled.
7.2.5.4. General setup
The section is for some general settings.
The temperature and pressure units can be changed with preferable ones.
Writing mode change the alignment in the WEB interface and SMS.
Hostname, System name, System location and System contact are sent in XML/JSON files and
can be used for flexible identification of the device. These parameters can be also included in
the body of the e-mails.
The checkboxes on the right define what to see on the “Monitoring page”. By default, they all
are enabled.