FreeWave WC45i-GW-485 User's Reference Manual

WC45i-GW-485 Modbus Gateway
User & Reference Manual
Part Number: LUM0086AA Revision: Mar-2018
The products described in this manual can fail in a variety of modes due to misuse, age, or malfunction and is not designed or intended for used in systems requiring fail-safe performance, including life safety systems. Systems with the products must be designed to prevent personal injury and property damage during product operation and in the event of product failure.
Warning! Remove power before connecting or disconnecting the interface or RF cables.
FreeWave Technologies, Inc. warrants the FreeWave® WC45i-GW-485 Modbus Gateway (Product) that you have purchased against defects in materials and manufacturing for a period of three years from the date of shipment, depending on model number. In the event of a Product failure due to materials or workmanship, FreeWave will, at its discretion, repair or replace the Product. For evaluation of Warranty coverage, return the Product to FreeWave upon receiving a Return Material Authorization (RMA). The replacement product will remain under warranty for 90 days or the remainder of the original product warranty period, whichever is longer.
IN NO EVENT WILL FREEWAVE TECHNOLOGIES, INC., ITS SUPPLIERS, OR ITS LICENSORS BE LIABLE FOR ANY DAMAGES ARISING
FROM THE USE OF OR INABILITY TO USE THIS PRODUCT. THIS INCLUDES BUSINESS INTERRUPTION, LOSS OF BUSINESS INFORMATION, INABILITY TO ACCESS OR SEND COMMUNICATION OR DATA, PERSONAL INJURY OR DAMAGE, OR OTHER LOSS WHICH MAY ARISE FROM THE USE OF THIS PRODUCT. THE WARRANTY IS EXCLUSIVE AND ALL OTHER WARRANTIES EXPRESS OR IMPLIED, INCLUDING BUT NOT LIMITED TO ANY WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR USE ARE EXPRESSLY DISCLAIMED.
FreeWave’s Warranty does not apply in the following circumstances:
1. If Product repair, adjustments, or parts replacements are required due to accident, neglect, or undue physical, electrical, or electromagnetic stress.
2. If Product is used outside of FreeWave specifications as stated in the Product's data sheet.
3. If Product has been modified, repaired, or altered by Customer unless FreeWave specifically authorized such alterations in each instance in writing.
FreeWave Technologies, Inc.
5395 Pearl Parkway, Suite 100
Boulder, CO 80301
303-381-9200
Toll Free: 1-866-923-6168
Fax: 303-786-9948
Copyright © 2018 by FreeWave Technologies, Inc. All rights reserved.
www.freewave.com
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WC45i-GW-485 Modbus Gateway: User & Reference Manual
Table of Contents
Preface 5
1. Overview 7
1.1. Operation 8
1.1.1. Remote WC45i-GW-485s and Non-sleeping Radio Only Endpoints 8
1.1.2. Remote WC45i-GW-485 Endpoint Re-Scan 8
2. Equipment 9
2.1. Included Equipment 9
2.1.1. User-supplied Equipment 9
3. WC45i-GW-485 Connections 10
3.1. Connections 11
3.1.1. Connections - WC45i-BB 11
3.2. Power and Gateway Connections 13
4. WC Toolkit Installation 14
5. WC Toolkit Update 21
6. Configuration 24
7. Gateway Event Log 30
8. Firmware Updates 32
8.1. Gateway Firmware Update 33
8.2. RadioFirmware Update 35
8.3. Rescue Gateway (ARM) Bootload 37
9. Remote Endpoint Configuration 40
10. Remote Shutdown (RSD) and Local Digital Output Control 44
10.1. Example: WC45i-GW-485 Modbus Gateway Topology 45
10.2. Remote Shutdown Configuration 46
11. Slave Register Remapping 48
12. Modbus Gateway Register Map 51
12.1. Boolean Registers 52
12.2. Read / Write Registers 52
12.3. Read-only Registers 53
13. WC Toolkit Software Environment 56
13.1. Device Configuration window 57
13.1.1. Modbus Slaves Reporting table 62
13.2. Edit Configurationwindow 64
13.2.1. Edit Configuration window - General Sensor 65
13.3. Firmware Updates window 71
13.3.1. Update Gateway Firmware menu - Firmware Updates window 71
13.3.2. Update Radio Firmware menu - Firmware Updates window 72
13.4. Gateway Log window 73
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13.4.1. Gateway Log tab 74
13.4.2. Log Statistics tab 76
13.5. (RegisterView) Slave 1 window 80
13.6. Remote Shutdown Settings window 84
13.6.1. Source Node(Endpoint) area 86
13.6.2. Relay Control Logic Section 88 Relay Details 88
13.6.3. Destination Counter/ RSD Stick Section 90
13.7. Slave Register Remapping window 91
14. WAVECONTACT Network Frequencies 95
14.1. Radio Network Group Selection: 0, 1, 2, or 3 96
14.2. Radio Network Group Selection: 4, 5, 6, or 7 97
14.3. Radio Network Group Selection: 8, 9, 10, 11 98
14.4. Radio Network Group Selection: 12, 13, 14, 15 99
14.5. Radio Network Group Selection: 16, 17, 18, or 19 100
14.6. Radio Network Group Selection: 20, 21, 22, 23 101
14.7. Radio Network Group Selection: 24, 25, 26, 27 102
14.8. Radio Network Group Selection: 28 or 29 103
Appendix A: Technical Specifications 104
Appendix B: Connection Troubleshooting 106
Appendix C: LEDs 107
Appendix D: Available Accessories 108
Appendix E: FreeWave Legal Information 109
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WC45i-GW-485 Modbus Gateway: User & Reference Manual
Document Description
FreeWave Part Number
User Manual The User Manual provides setup, configuration, andsafety
information for the WC45i-GW-485.
LUM0086AA
Quick Start Guide The Quick Start Guide provides the out-of-the-box setup of
the WC45i-GW-485.
QSG0035AA
ApplicationNote Remote Shutdown System LAN5510AA

Preface

Contact FreeWave Technical Support
For up-to-date troubleshooting information, checkthe Support page at www.freewave.com. FreeWave provides technical support MondaythroughFriday, 8:00 AM to 5:00 PM Mountain
Time (GMT -7).
l Call toll-free at 1-866-923-6168. l In Colorado, call 303-381-9200. l Contact us through e-mail at moreinfo@freewave.com.
Other WAVECONTACT Information
Use the FreeWave http://support.freewave.com/ website to download the latest versionof these documents. Registration is required to use this website.
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Preface
Document Styles
This document uses these styles:
l Parameter setting text appears as: [Page=radioSettings] l File names appear as: configuration.cfg. l File paths appear as: C:\Program Files (x86)\FreeWave Technologies. l User-entered text appears as: xxxxxxxxx.
Caution: Indicates a situationthat MAY cause damage to personnel, the radio, data, or network.
Example: Provides example information of the related text.
FREEWAVE Recommends: Identifies FreeWave recommendation information.
Important!: Provides crucial information relevant to the text or procedure.
Note: Emphasis of specific information relevant to the text or procedure.
Provides time saving or informative suggestions about using the product.
Warning! Indicates a situation that WILL cause damage to personnel, the radio, data, or network.
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WC45i-GW-485 Modbus Gateway: User & Reference Manual

1. Overview

Thank you for purchasing the WC45i-GW-485 Modbus Gateway. The WAVECONTACT WC45i-GW-485 has these features:
l AES 128-bit Encryption l Class 1 Division 2 Area certification l RS485 connection to a Modbusmaster device. l Wide range DC power input: +6 to +36VDC. l Collectsand cachesModbus data from all WAVECONTACT remote devices. l Providesconfiguration and status registers for remote configuration and status monitoring. l Stores a maximum of 4700 register values from any combination of remote Endpoints. l Supports transparent Modbus mode. l Internal Remote Shut Down (RSD) logic control option. l Slave register re-mapping. l Remote configuration of WAVECONTACT devicesthrough an Ethernet Gateway
connection.
l Remote sensor configuration (PACTware™ and RadarMaster). l Integrated500mW FHSS 900MHz ISM band radio and high gain antenna.
Note: The terms node and Endpoint are used interchangeably in this document.
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1. Overview

1.1. Operation

The WC45i-GW-485 supports all remote WAVECONTACT Endpoints. This allows all remote sensor data to be available in Modbus format.
l The register data from remote sensor Endpointsis available by requesting the remote
Endpoint’s Modbus Slave ID and register address from that Endpoint’s register map.
l The WC45i-GW-485:
l responds with the most recent copy of the data from the remote Endpoint. l automatically times out data from a remote Endpoint it stops receiving data for.

1.1.1. Remote WC45i-GW-485s and Non-sleeping Radio Only Endpoints

l Pre-configured remote Endpoints forward their set of registers to the Modbus Gateway on
a pre-defined schedule (1 minuteto 5 minutes is typical).
l The register data is then buffered in the Gateway and can be read by the RTU at any
time.
l If a Modbus request is received by the WC45i-GW-485 for a Modbus ID and address where
buffered data does NOT exist but the Modbus ID is known, the Modbus request is forwarded to the remote Modbus Endpoint over the WAVECONTACT network.
l The response is returned to the RTU.
l If a request for multiple registersis issued by the RTU AND if the WC45i-GW-485 does
NOT have all registered data buffered, an exception is returned.
l The system will NOT combine buffered and transparent data within a single Modbus
response.

1.1.2. Remote WC45i-GW-485 Endpoint Re-Scan

It is possibleto cause a remote WC45i-GW-485 to re-scan for attachedModbus devices by writing to one of the Gateway’s configuration registers.
l This is useful to discover a Modbus device that is added to an existing Modbus Endpoint. l The scan may be initiated by one of these methods:
l If the radio address of the Gateway is known, writing this address to Gateway register
3000 will result in a scan.
l If the ModbusID of one of the already registered devices attached to a WC45i-GW-485 is
known, a scan is started by writing the ID to Gateway register 3002.
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WC45i-GW-485 Modbus Gateway: User & Reference Manual
Included Equipment - WC45i-GW-485
Qty Description
1 WC45i-GW - Gateway with Modbus Interface and 25ft cable 1 WC45i-BB - Smart Breakout Board 1 WC45i-GW-485 Quick Start Guide

2. Equipment

2.1. Included Equipment

The WC45i-GW-485 package contains these items:

2.1.1. User-supplied Equipment

l Small, flathead screwdriver l Mounting equipment for the WC45i-GW-485. l USB to Serial DB9 programming cable (FreeWave Part #: WC-USB-DB9) l DC Adapter Power Supply (+6 to +36VDC) l Barrel connector with Ground and Power flying leads l Computer for WAVECONTACT device configuration.
Note: See Available Accessories (on page 108) for additional equipment.
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WC45i-GW-485 Modbus Gateway: User & Reference Manual

3. WC45i-GW-485 Connections

l Connections (on page 11) l Power and Gateway Connections(on page 13)
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3. WC45i-GW-485 Connections

3.1. Connections

Important!: The WC45i-GW-485 Modbus Gateway is configured using the WC Toolkit.
Downloadthe WC Toolkit software from http://support.freewave.com/. Registration is required to use this website.
Note: The RS232 Config / Debug connector on the WC45i-GW MUST be used for WC Toolkit access. The Config / Debug port is accessed by a direct connection to the WC45i-GW-485 RS232 Config / Debug connector port.
The WC45i-GW-485 usesa 6-conductor cable and the WC45i-BB Smart Breakout Board for power and serial communications.

3.1.1. Connections - WC45i-BB

The WC45i-BB Smart Breakout Board (FreeWave Part #: WC45i-BB, Figure 1), is used to:
l Connect to the RS232 lines (#2) l Configure the WC45i-GW-485 system (#4). l Power the WC45i-GW-485 (#5).
Important!: The Signal Strength LEDs (#3) do NOT light at the Gateway as multiple Endpoints with
varying signal strength may be connected at one time.
Figure 1: WC45i-BB Smart Breakout Board used with the WC45i-GW-485
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WC45i-GW-485 Modbus Gateway: User & Reference Manual
WC45i-BB Smart Breakout Board Connections
Location # Title Description
1 RS485 Modbus
Block
Connect the Modbus master to the RS485 Modbus Block.
2 RS232 RS232
Config / Debug
connector
The RS232 Config / Debug connector is for the USB to Serial DB9 programming cable (FreeWave Part # WC-USB-DB9).
3 Signal Strength
LEDs
See LEDs (on page 107) for detailed information.
4 l BRN-B
l GRN-A l YEL-RX l ORG-TX l BLK-GND l RED-PWR
l RS485B - 9600 Baud l RS485A - 9600 Baud l RS232Config / Debug connector RX - 9600 Baud l RS232Config / Debug connector TX - 9600 Baud l Ground l Positive Power (+6 to +36VDC)
5 PWR
GND
Power Source from an external power supply of +6 to +36VDC. External power ground.
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3. WC45i-GW-485 Connections

3.2. Power and Gateway Connections

Important!: Verify the items listed in Equipment (on page 9) are availablebefore starting this
procedure. It is assumed that the readerand installer have completed the FreeWave WC45i-GW-485 installation andsetup training to follow the procedures in this document.
1. All wiring shouldbe neat and orderly.
2. On the WC45i-BB Smart Breakout Board:
a. Connect the configuration wires of the Gateway to their respectivecolor-designated
screw terminal connections.
b. Connect the Serial end of the WC-USB-DB9 cable to the RS232 Config / Debug
connector port and the USB connection to the computer.
c. Use the PWR screw terminal connection to connect the Power Source from an
external power supply of +6 to +36VDC. d. Use the GND screw terminal connection to connect the External power ground. e. Connect the Modbus master to the RS485 Modbus Block.
The WC45i-BB connections are similar to Figure 2:
Figure 2: WC45i-BB Connections
3. If this is the first time the WC45i-GW-485 is installed, wait for the drivers to install.
Important!: Depending on the computer and connection, the driverinstallationcan take 3-6
minutes.
4. Continue with:
l WC Toolkit Installation (on page 14) l Configuration (on page 24)
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WC45i-GW-485 Modbus Gateway: User & Reference Manual

4. WC Toolkit Installation

Note: The images in this procedure are for Windows® 7 and/or Firefox®.
The dialog boxes and windows may appear differently on each computer.
1. Click http://support.freewave.com/. The FreeWave Support site opens.
Important!: Registration is required to use this website.
Figure 3: FreeWave Login window
2. Enter the User Name and Password.
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4. WC Toolkit Installation
3.
Click . A successful Login message briefly appears. The Help Topics window opens.
4. Click the Software link.
Figure 4: Help Topics window
The Software window opens.
5. Click the WAVECONTACT Toolkit link.
Figure 5: Software window
The available software appears in the window.
6. Select and click the attachment.
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WC45i-GW-485 Modbus Gateway: User & Reference Manual
Figure 6: WAVECONTACT Toolkit window
The Opening dialog box opens.
Figure 7: WC Toolkit Opening dialog box
Note: This procedure shows Firefox® dialog boxes.
Otherbrowsers will have different dialogboxes andprocedures.
7. Click OK. The Enter name of file to save to dialog box opens.
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4. WC Toolkit Installation
Figure 8: Enter name of file to save to dialog box
8. Search for and select a location to save the .zip file to and click Save. The Enter name of file to save to dialog box closes.
9. Open a Windows® Explorer window and find the location where the .zip file was saved.
10. Double-click the .zip file.
11. Extract the .exe file from the .zip file into a parent location.
12. Double-click the .exe file to run the WC Toolkit installer. The Open File - Security Warning dialog box opens.
Figure 9: Open File - Security Warning dialog box
13. Click Run. The User Account Control dialog box opens.
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Figure 10: User Account Control dialog box
14. Click Yes. The WC Toolkit Setup Wizard starts.
WC45i-GW-485 Modbus Gateway: User & Reference Manual
Figure 11: WC Toolkit Setup Wizard - Select Destination Location window
15. Click Next to continue. The Ready to Install window opens.
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4. WC Toolkit Installation
Figure 12: WC Toolkit Setup Wizard - Ready to Install window
16. Click Install. The installprocess is very quick. The Installation Complete window opens.
Figure 13: WC Toolkit Setup Wizard - Installation Complete window
17. Click Finish to open WC Toolkit. An Update message appears in the WC Toolkit window is an update is available.
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WC45i-GW-485 Modbus Gateway: User & Reference Manual
Figure 14: WC Toolkit - Update Available message
18. Continue with the WC Toolkit Update (on page 21) procedure.
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WC45i-GW-485 Modbus Gateway: User & Reference Manual

5. WC Toolkit Update

If the WAVECONTACT device is connected to the internet, WC Toolkit automaticallysearches for an update for either the WC Toolkit itself or the connected device's firmware.
An Update Available message appears if an update is available.
Note: An Update Available message also appears in the Device Configuration window (onpage 57) for any connected WAVECONTACT device when an update is availablefor that device. The update procedure is the same for the device and WC Toolkit.
1. Open the WC Toolkit software. The Update Available message appears in the window. (Figure 15)
Figure 15: WC Toolkit - Update Available message
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5. WC Toolkit Update
2. Click the Update Available message link.
Figure 16: Click the Update Available message link
The Open File - Security Warning dialog box opens.
Figure 17: Open File - Security Warning dialog box
3. Click Run. The User Account Control dialog box opens.
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WC45i-GW-485 Modbus Gateway: User & Reference Manual
Figure 18: User Account Control dialog box
4. Click Yes. The WC Toolkit update processis very quick. When the update is completed, WC Toolkit re-opens the Select Device window showing the updated software version in the WC Toolkit window. (Figure 19)
Figure 19: Select Device window
5. Continue with Configuration of the WC45i-GW-485.
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WC45i-GW-485 Modbus Gateway: User & Reference Manual

6. Configuration

Note: The terms node and Endpoint are used interchangeably in this document.
FREEWAVE Recommends: Install and configurethe WC45i Gateway before any Endpoints to
ensure the Endpoints have connectivity after installation.
Important!: The WC45i-GW-485 Modbus Gateway is configured using the WC Toolkit.
Downloadthe WC Toolkit software from http://support.freewave.com/. Registration is required to use this website.
Important!: The RS232 Config / Debug connector on the WC45i-GW MUST be used for WC
Toolkit access. The Config / Debug port is accessed by a direct connection to the WC45i-GW-485 RS232 Config / Debug connector port.
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6. Configuration
Procedure
Note: The screenshots are examples only.
The dialog boxes and windows appear differently on each computer.
1. Verify the WC Toolkit software is installed on the computer connected to the WC45i-GW-
485.
Note: See WC Toolkit Installation (on page 14) and WC Toolkit Update (on page 21).
2. Open the WC Toolkit software. The Select Device window opens. (Figure 20)
Figure 20: Select Device window
3. Click the Refresh button to have WC Toolkit search for and list the available COM ports reported by Windows and connected devices in the COM Port list box.
4. Click the COM Port list box arrow and select the COM port on the computer associated with the connected WC45i-GW-485.
5. Click the Auto-Detect Device on COM Port button to have WC Toolkit connect the device to the COM Port selected in the COM Port list box.
Note: Optional: Click the Select Device list box arrow and select the connected WC45i- Gateway device. Click the Open Device Window button to open the Device Configuration window (on page
57).
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WC45i-GW-485 Modbus Gateway: User & Reference Manual
Figure 21: Select Device list box
The Device Configuration window opens for the selected device.
Note: See Device Configuration window (on page 57) for detailed information.
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6. Configuration
Figure 22: Device Configuration window: WC45i-Gateway
6. In the Settings area (#5), change these settings:
Note: The Network settings are used to create separate networks using multiple Gateways
(that are in close proximity to oneanother).
Important!: The Radio Network andRadio Network Group settings are selected by the
user but MUST MATCH the existing Gateway network for successful communication between the Gateway and Endpoint. See WAVECONTACT Network Frequencies (on page 95) for additional information.
a. Click the Radio Network list box arrow and select 0 (zero) to 7 for the assigned
number.
b. Click the Radio Network Group list box arrow and select 0 (zero) to 29 for the network
group assigned number.
c. Click the Set button to save the information.
7. In the Set Encryption Key area (#6), change these settings:
a. In the Key text box, enter the encryption key for the device using 6 to 16 characters. b. Click the Set button to save the information.
Important!: A Key CANNOT contain spaces or angle brackets.
The Gateway andEndpoints only communicate if they areconfigured with the same Key. When setting up a new network, use this same encryption Key on all the devices.
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WC45i-GW-485 Modbus Gateway: User & Reference Manual
Note: When the WC45i-GW-485 drops its network, it attempts to join networks using the same encryption Key.
Caution: It is possible to hide the encryption Key so it cannot be read. This is the most secure option, but if the Key is forgotten, there is no way to recover it. The Key must be reset on every device on the network.
8. Optional: Click the Settings menu and select Set Encryption Key Unrecoverable to permanently hide the key.
Figure 23: Settings menu > Set Encryption Key Unrecoverable
9. Click Refresh List button to update the Modbus Slaves Reporting table with all connected remote Endpoints.
Figure 24: Modbus Slaves Reporting table
10. Configure the Endpoints attached to the WC45i-GW-485.
Note: Use the Configuration procedure in the User Manual for these WAVECONTACT Endpoints: WC15i Multi-Input C1D1 Endpoint, WC20i Endpoint, WC30i Wireless Pressure Sensor, WC40i Modbus Endpoint, WC40i-COUNT CounterEndpoint, or WC40i-MB-RSD Modbus Endpoint.
11. Optional: On the WC20i or WC45i-GW-485Endpoint, press the Check-in button to apply power to the configured sensor, read the sensor values, and send the collected sensor data to the Gateway.
12. Verify the Gateway is communicating with the Endpoints.
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6. Configuration
Note: A successful connection on the WAVECONTACT Endpoint is indicatedwith Green blinking TX and ACT lights and a Red blinking light for RX. If the connection is NOT successful, a Green blinking TX light appears for 10 seconds.
13. If applicable, continue with these other WC45i configuration procedures:
l Remote Endpoint Configuration (on page 40) l Remote Shutdown (RSD) and Local Digital Output Control (on page 44) l Slave Register Remapping (on page 48)
14. Close the WC Toolkit software.
15. Remove the WC-USB-DB9 USB to Serial DB9 programming cable from the computer and the WC45i-BB.
16. As applicable, replace the Endpoint cover.
17. Mount the Gateway device.
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WC45i-GW-485 Modbus Gateway: User & Reference Manual

7. Gateway Event Log

The Gateway keeps an internal log of eventsthat are viewed in the Gateway Log window (on
page 73) of WC Toolkit.
The Gateway Log window is used to log eventssuch as reboots, remote Endpoints joining and/or timing out, localRSD control events, remote configuration sessions, firmware updates, etc.
Procedure
Note: The terms node and Endpoint are used interchangeably in this document.
1. Open the Device Configuration window (on page 57).
2. On the Tools menu, click View Gateway Log.
Figure 25: Tools menu > View Gateway Log
The Gateway Log window opens. The Gateway Log tab is active.
LUM0086AA Rev Mar-2018 Page 30 of 112 Copyright © 2018FreeWave This document is the property of FreeWave Technologies, Inc. and contains proprietary information owned by
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