Moxa Technologies ioPAC 5500, ioPAC 5542-C-T, ioPAC 5542-HSPA-C-T, ioPAC 5542-IEC-T, ioPAC 5542-HSPA-IEC-T Hardware User Manual

ioPAC 5500 Hardware User’s Manual

Edition 2.0, June 2017

www.moxa.com/product

© 2017 Moxa Inc. All rights reserved.

ioPAC 5500 Hardware User’s Manual

The software described in this manual is furnished under a license agreement and may be used only in accordance with

the terms of that agreement.

Copyright Notice

© 2017 Moxa Inc. All rights reserved.

Trademarks

The MOXA logo is a registered trademark of Moxa Inc.

All other trademarks or registered marks in this manua l belong to their res pec ti v e manufacturers.

Disclaimer

Information in this document is subject to change witho ut no tic e a nd doe s not repres e nt a co mmitment o n the part of
Moxa.

Moxa provides this document as is, without warranty of any kind, either expressed or implied, including, but not limited
to, its particular purpose. Moxa reserves the rig ht to make impro vem e nts and/o r changes to this manual, or to the
products and/or the programs described in this manual, at any time .

Information provided in this manual is intended to be accurate and reliable. However, Moxa assumes no responsibility for
its use, or for any infringements on the rights of third parties that may res ult fr om its use.

This product might include unintentional technic al o r typographical errors. Changes are periodically made to the
information herein to correct such error s , and these changes are inc or pora te d into new editions of the publication.

Technical Support Contact Information

www.moxa.com/support

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-free: 1-888-669-2872

Tel:

[phone]

Fax:

[phone]

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-free: 800-820-5036

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Table of Contents

1. Introduction ...................................................................................................................................... 1-1

Overview ........................................................................................................................................... 1-2

Package Checklist ............................................................................................................................... 1-2

Appearance and Dimensions ................................................................................................................ 1-3

Appearance ................................................................................................................................ 1-3

Dimensions................................................................................................................................. 1-4

Hardware Block Diagrams .................................................................................................................... 1-4

ioPAC 5500 RTU Controller Block Diagram ...................................................................................... 1-4

Product Hardware Specifications ........................................................................................................... 1-6

Product Selection Guide ............................................................................................................... 1-6

Product Specifications .................................................................................................................. 1-6

2. Installation ....................................................................................................................................... 2-1

Basic Installation ................................................................................................................................ 2-2

DIN Rail Installation Procedure ...................................................................................................... 2-2

Configuring the Power ......................................................................................................................... 2-3

Powering on the ioPAC Controller .................................................................................................. 2-3

Grounding the ioPAC .................................................................................................................... 2-3

Installing a microSD Card .................................................................................................................... 2-4

ioPAC 5500 LED Indicators ................................................................................................................... 2-5

System LEDs .............................................................................................................................. 2-6

Communication LEDs ................................................................................................................... 2-6

Cellular ...................................................................................................................................... 2-6

User-Defined LEDs: LED1 and LED2 ............................................................................................... 2-6

IEC-61131-3 Compliant LEDs: R/S and ERR .................................................................................... 2-6

I/O LEDs .................................................................................................................................... 2-6

The Toggle Switch .............................................................................................................................. 2-7

In IEC-61131-3 Models ................................................................................................................ 2-7

In C/C++ Models ........................................................................................................................ 2-7

Toggle Switch: Factory Reset Process .................................................................................................... 2-7

Pin assignment and I/O wiring guide ..................................................................................................... 2-8

Pin Assignment ........................................................................................................................... 2-8

Digital Input ............................................................................................................................... 2-9

Digital Output ............................................................................................................................. 2-9

Analog Input (Voltage) ................................................................................................................. 2-9

Analog Input (Current) ................................................................................................................. 2-9

Installing a SIM card ......................................................................................................................... 2-10

Connecting to the Network ................................................................................................................. 2-10

Ethernet Communication ............................................................................................................ 2-10

Serial Connectivity ............................................................................................................................ 2-11

Connecting to a Serial Device ..................................................................................................... 2-11

Serial Console (Debug Port) ........................................................................................................ 2-12

Battery ............................................................................................................................................ 2-13

3. The RTUxpress Utility ........................................................................................................................ 3-1

RTUxpress Introduction ....................................................................................................................... 3-2

Quick Start ................................................................................................................................. 3-3

User Interface ............................................................................................................................. 3-6

Device and Service Configuration ........................................................................................................ 3-16

Settings Page ........................................................................................................................... 3-16

Log Message Window ................................................................................................................. 3-16

1

1. Introduction

The following topics are covered in this chapter :



Overview



Package Checklist



Appearance and Dime ns io n s

 Appearance
 Dimensions



Hardware Block Diagrams

 ioPAC 5500 RTU Controller Block Diagram



Product Hardware Specifications

 Pr o duct Selection Guide
 Pr o duct Specifications

ioPAC 5500 Hardware Introduction

1-2

Overview

The ioPAC 5500 standalone controllers use an ARM9 based industrial-grade CPU for the main system, with ARM
Cortex™ M4 based CPUs fo r the I/O channels. The USB bus between the controller CPU and module CPUs
transmits data at up to 200 Mbps, and the dual CPU architecture supports a 2 kHz analog input sampling rate
and millisecond timestamps. The ioPAC 5500 supports C/C++ and IEC 61131-3 programming, rail-level surge
and ESD protection, a -40 to 75°C (-30 to 75°C for HSPA models) operating temperature range, UL/cUL Class
1 Division 2 certification, two 10/100 Mbps Ethernet ports with two MACs (Port Trunking ready), and two 3-in-1
serial ports. With Moxa's Active OPC Server and DA-Center, the ioPAC 5500 series provides a comprehens ive
solution for data acquisition and contro l app lic a tio ns in har sh env i ro nme nts .

Package Checklist

ioPAC 5500

The ioPAC 5500 ships with the following items:

• ioPAC 5500 controller

• Serial console cable (C/C++ models only)

• Documentation and software CD

Optional Accessories (can be purchased separately)

• DK-DC50131: DIN-rail mounting kit, 50 x 131 mm

• CBL-RJ458P-100: 8-pin RJ45 CAT5 Ethernet cable, 100 cm

• CBL-F9DPF1x4-BK-100: Serial console cable

• WK-51-01: Wall-mounting kit, 2 plates with 6 screws

• ANT-WCDMA-AHSM-04-2.5m Black: 3G cellular antenna

ioPAC 5500 Hardware Introduction

1-3

Appearance and Dimensions

Appearance

The following figures depict ioPAC 5500 RTU controller.

Front View

Top View

ioPAC 5500 Hardware Introduction

1-4

Dimensions

Unit: mm (inch)

Hardware Block Diagrams

ioPAC 5500 RTU Controller Block Diagram

CPU Board

ioPAC 5500 Hardware Introduction

1-5

I/O Board

3G Board

ioPAC 5500 Hardware Introduction

1-6

Product Hardware Specifications

Product Selection Guide

Model Name Description

ioPAC 5542-C-T RTU controller, 8AIs, 8 DIs, 8DIOs, C/C++, -40 to 75°C operating

temperature

ioPAC 5542-HSPA-C-T RTU controller with HSPA module, 8AIs, 8 DIs, 8DIOs, C/C++, -30 to 75°C

operating temperature

ioPAC 5542-IEC-T RTU controller, 8AIs, 8 DIs, 8DIOs, IEC 61131-3, -40 to 75°C operating

temperature

ioPAC 5542-HSPA-IEC-T RTU controller with HSPA module, 8AIs, 8 DIs, 8DIOs, IEC 61131-3, -30 to

75°C operating temperature

NOTE

Conformal coating available on reques t.

Product Specifications

Computer

Main CPU:

32-bit ARM9 192 MHz CPU

I/O CPU:

32-bit ARM Cortex M4 80 MHz CPU

OS:

Linux

Clock:

Real-time clock with battery backup

Memory:

•

SDRAM: 64 MB

• Flash: 32 MB

• SRAM: 256 KB (battery backup lasts for 1 week)

• microSD™ Slot: Up to 32 GB (SD 2.0 compatible)

Note: For units operating in extreme temperatures , industrial grade, wide

-temperature microSD cards are

required.

Cellular (for the ioPAC 5542-HSPA Series)

Network:

• Quad

-band GSM/GPRS/EDGE 850/900/1800/1900 MHz

• Five

-band UMTS/ H S P A + 800/850/AWS /1900/2100 MH z

Internet:

HSPA:

• Up to 5.76 Mbps upload speed

• Up to 14.4 Mbps download speed
UMTS: Up to 384 kbps upload/downloa

d speed

EDGE Class 12: Up to 237 kbps upload/download speed
GPPRS Class 12: Up to 85.6 kbps upload/download speed

SMS:

Point-to-Point Text/PDU mode

SIM Control Voltage:

3/1.8 V

Ethernet Interface

LAN:

2 x 10/100 Mbps, 2 MACs (IPs), RJ45

Protection:

1.5 kV magnetic isolation

Serial Communication

Interface:

• 2 RS

-232/422/485 ports, software selectable (DB9 male)

• 1 RS

-232 debug port (4-pin connector)

Serial Line P r ot ec tion:

15 kV ESD for all signals

ioPAC 5500 Hardware Introduction

1-7

Serial Communication Para me ters

Parity:

None, Even, Odd

Data Bits:

7, 8

Stop Bits:

1, 2

Flow Control:

RTS/CTS, XON/XOFF

Baudrate:

300 bps to 921. 6 kbps

Serial Signals

RS

-232: TxD, RxD, DTR, DSR, RTS, CTS, DCD, GND, RI

RS

-422: Tx+, Tx-, Rx+, Rx-, GND

RS

-485-4w: Tx+ , Tx-, Rx+, Rx-, GND

RS

-485-2w: Data+, Data-, GND

Inputs and Outputs

Analog Inputs:

8 channels

Digital Inputs:

8 channels

Configurable DIOs:

8 channels

Isolation:

3k VDC or 2k Vrms

Analog Input

Type: Differential Inp ut

Resolution:

16 bits

I/O Mode:

Voltage / Current

Input Range:

0 to 10 VDC, -10 to 10 VDC , 0 to 20 mA , 4 to 20 m A (w i re off)

Historical Data Buf fering:

60KB per channel, 120 second data buffer at 250 Hz

Accuracy:

±0.1% FSR @ 25°C
±0.3% FSR @

-40 and 75°C

Sampling Rate:

• All

channels: 2000 samples/sec

• Per channel: 250 samples/sec

Input Impedance:

2M ohms (min.)

Built

-in Resistor for Current Input: 120 ohms (min.)

Digital Input

Sensor Type:

Wet Contact (NPN or PNP), Dry Contact

I/O Mode:

DI, Counter or Frequency

Dry

Contact:

• On: short to GND

• Off: open

Wet Contact:

NPN (DI to GND):

• On: 0 to 3 VDC

• Off: 10 to 30 VDC
PNP (DI to GND):

• Off: 0 to 3 VDC

• On: 10 to 30 VDC

Common Type:

4 points per COM

Counter Frequency:

1 kHz

Digital Filtering Time Interval:

Software selectable (by 0.5 ms)

Digital Output

Type:

Sink

I/O Mode:

DO or PWM

Pulse Output Freque nc y:

1 kHz

Over

-voltage Protection: 45 VDC

Over

-current Protection: 2.6 A (4 channels @ 650 mA)

Over

-temperature Shutdown: 175°C (typical), 150°C (min.)

Current Rat ing:

200 mA per channel

ioPAC 5500 Hardware Introduction

1-8

Software Characteristics

Automation Languages: C/C++, IEC 6 11 31-3

Protocols:

Modbus TCP/RTU (master/slave), SNMP TCP/IP, UDP, DHCP, BOOTP, S NTP, SMTP

Power Requiremen t s

Power

Input:

• ioPAC 5542

-HSPA series: 305 mA @ 24 VDC

• ioPAC 5542 series: 264 mA @ 24 VDC

Physical Characteristics

Housing:

Aluminum

Dimensions:

90.05 x 135 x 105.4 mm (3.55 x 5. 32 x 4.15 in)

Weight:

• ioPAC 5542

-HSPA Series: 1100 g (2.43 lb)

• ioPA C 5542 Series: 1000 g (2.20 l b )

Mounting:

DIN-Rail mounting (standard), wa ll mounting (op tional)

Connector:

Spring-type terminal block

Environmental Limits

Operating Temperature:

• ioPAC 5542 Series :

-40 to 75°C (-40 to 176°F)

• ioPAC 5542

-HSPA Series: -30 to 75°C (-2 2 to 176°F)

Storage Temperature:

-40 to 85°C (-40 to 185°F)

Ambient Relative Humidity:

5 to 95% (non-condensing)

Shock:

IEC 60068-2-27

Vibration:

IEC 60068-2-6

Altitude:

Up to 2000 m

Note: Please contact Moxa if you require products

guaranteed to function properly at higher altitudes.

Standards and Cer tifications

Safety:

UL 508

EM

C: EN 55022/ 24

EMI:

FCC Part 15 Subpart B Class A, CISPR 22

EMS:

IEC 61000

-4-2 ESD: Contact: 4 kV; Air: 8 kV

IEC 61000

-4-3 RS: 80 MHz to 1000 MHz: 3 V/m

IEC 61000

-4-4 EFT: Power: 1 kV; Signal: 0.5 kV

IEC 61000

-4-5 Surge: Power: 2 kV (L-PE), 1 kV (L-L); Signal: 1 kV

IEC 61000

-4-6 CS: 3 V

IEC 61000

-4-8 PFMF: 1 A/m

Radio

: NCC

Rail Traffic:

EN 50121-4

Hazardous Location:

Class 1 Division 2

Note: Please check Moxa’s website for the most up-to-date certification status.

Warranty

Warranty Period:

5 years

Details:

See www.moxa.com/warranty

2

2. Installation

This chapter includes instructions on how to insta ll the io PAC 5500.
The following topics are covered in this chapter :



Basic Installation

 DIN Rail Installation Procedure



Configuring the Power

 Powering on the ioPAC Controller
 Grounding the ioPAC



Installing a microSD Card



ioPAC 5500 LED In di c a tor s

 System LEDs
 Communication LEDs
 Cellular
 User-Def ined LEDs : LED1 and LED2
 IEC-61131-3 Compliant LEDs: R/S and ERR
 I/O LEDs



The Toggle S witch

 In IEC-61131-3 Models
 In C/C++ Models



Toggle Switch: Factory Reset Process



Pin assignment and I/ O wi r ing gui de

 Pin As s ignment
 Di g ital Input
 Di g ital O utp ut
 Analog Input

(Voltage)

 Analog Input

(Current)



Installing a SIM card



Connecting to the Network

 Ethernet Communication



Serial Connectivity

 Connecting to a Serial Device
 Se rial Console (Debug Port)



Battery