Weidmuller WI-GTWY-9, WI-GTWY-9-MD1 User Manual

WI-GTWY-9-xxx Wireless Gateway User Manual V1.18

User Manual

WI-GTWY-9-xxx Wireless Gateway

Weidmuller Inc., 821 Southlake Blvd., Richmond, VA 23236

Tel: (804) 794-2877 Fax: (804) 897-4136

Web: www.weidmuller.com

WI-GTWY-9-xxx Wireless Gateway Introduction v1.18

Thank you for your selection of the WI-GTWY-9 module. We trust it will give

you many years of valuable service.

ATTENTION!

Incorrect termination of supply wires may

cause internal damage and will void warranty.

To ensure your WI-GTWY-9 enjoys a long life,

double check ALL your connections with

the user’s manual

before turning the power on.

Caution!

For continued protection against risk of fire, replace the module fuse F1 only with the same type and rating.

CAUTION:

To comply with FCC RF Exposure requirements in section 1.1310 of the FCC Rules, antennas used with this device must be installed to provide a separation distance of at least 20 cm from

all persons to satisfy RF exposure compliance.

DO NOT:

• operate the transmitter when someone is within 20 cm of the antenna

• operate the transmitter unless all RF connectors are secure and any open connectors are

properly terminated.

• operate the equipment near electrical blasting caps or in an explosive atmosphere

All equipment must be properly grounded for safe operations. All equipment should be serviced only by a qualified technician.

WI-GTWY-9-xxx Wireless Gateway User Manual V1.18

FCC Notice: WI-I/O 9-x Wireless I/O Module

This user’s manual is for the WI-GTWY-9-xxx radio telemetry module. This device complies with Part 15.247 of the FCC Rules. Operation is subject to the following two conditions:

1) This device may not cause harmful interference and

2) This device must accept any interference received, including interference that may cause undesired operation.

This device must be operated as supplied by Weidmuller, Inc. Any changes or modifications made to the device without the written consent of Weidmuller, Inc. May void the user’s authority to operate the device.

End user products that have this device embedded must be supplied with non-standard antenna connectors, and antennas available from vendors specified by Weidmuller, Inc.. Please contact for end user antenna and connector recommendations.

Notices: Safety

Exposure to RF energy is an important safety consideration. The FCC has adopted a safety standard for human exposure to radio frequency electromagnetic energy emitted by FCC regulated equipment as a result of its actions in Docket 93-62 and OET Bulletin 65 Edition 97-

01.

CAUTION:

To comply with FCC RF Exposure requirements in section 1.1310 of the FCC Rules, antennas used with this device must be installed to provide a separation distance of at least 20 cm from all persons to satisfy RF exposure compliance.

DO NOT:

• operate the transmitter when someone is within 20 cm of the antenna

• operate the transmitter unless all RF connectors are secure and any open connectors are

properly terminated.

• operate the equipment near electrical blasting caps or in an explosive atmosphere

All equipment must be properly grounded for safe operations. All equipment should be serviced only by a qualified technician.

WI-GTWY-9-xxx Wireless Gateway Introduction v1.18

Limited Lifetime Warranty, Disclaimer and Limitation of Remedies

Weidmuller, Inc. products are warranted to be free from manufacturing defects for the “serviceable lifetime” of the product. The “serviceable lifetime” is limited to the availability of electronic components. If the serviceable life is reached in less than three years following the original purchase from Weidmuller, Inc., Weidmuller, Inc. will replace the product with an equivalent product if an equivalent product is available.

This warranty does not extend to:

- failures caused by the operation of the equipment outside the particular product's

specification, or

- use of the module not in accordance with this User Manual, or

- abuse, misuse, neglect or damage by external causes, or

- repairs, alterations, or modifications undertaken other than by an authorized Service Agent.

Weidmuller, Inc.’s liability under this warranty is limited to the replacement or repair of the product. This warranty is in lieu of and exclusive of all other warranties. This warranty does not indemnify the purchaser of products for any consequential claim for damages or loss of operations or profits and Weidmuller, Inc. is not liable for any consequential damages or loss of operations or profits resulting from the use of these products. Weidmuller, Inc. is not liable for damages, losses, costs, injury or harm incurred as a consequence of any representations, warranties or conditions made by Weidmuller, Inc. or its representatives or by any other party, except as expressed solely in this document..

WI-GTWY-9-xxx Wireless Gateway User Manual V1.18

Important Notice

Weidmuller, Inc.’s products are designed to be used in industrial environments, by experienced industrial engineering personnel with adequate knowledge of safety design considerations.

Weidmuller, Inc. radio products are used on unprotected license-free radio bands with radio noise and interference. The products are designed to operate in the presence of noise and interference, however in an extreme case, radio noise and interference could cause product operation delays or operation failure. Like all industrial electronic products, Weidmuller, Inc.’s products can fail in a variety of modes due to misuse, age, or malfunction. We recommend that users and designers design systems using design techniques intended to prevent personal injury or damage during product operation, and provide failure tolerant systems to prevent personal injury or damage in the event of product failure. Designers must warn users of the equipment or systems if adequate protection against failure has not been included in the system design. Designers must include this Important Notice in operating procedures and system manuals.

These products should not be used in non-industrial applications, or life-support systems, without consulting Weidmuller, Inc. first.

1. For WI-GTWY-9-xxx modules, a radio license is not required in most countries, provided the module is installed using the aerial and equipment configuration described in the WI-I/O 9-x Installation Guide. Check with your local WI-GTWY-9-xxx distributor for further information on regulations.

2. For WI-GTWY-9-xxx modules, operation is authorized by the radio frequency regulatory authority in your country on a non-protection basis. Although all care is taken in the design of these units, there is no responsibility taken for sources of external interference. The WI-I/O 9-x intelligent communications protocol aims to correct communication errors due to interference and to retransmit the required output conditions regularly. However some delay in the operation of outputs may occur during periods of interference. Systems should be designed to be tolerant of these delays.

3. To avoid the risk of electrocution, the aerial, aerial cable, serial cables and all terminals of the WI-GTWY-9-xxx module should be electrically protected. To provide maximum surge and lightning protection, the module should be connected to a suitable earth and the aerial, aerial cable, serial cables and the module should be installed as recommended in the Installation Guide.

4. To avoid accidents during maintenance or adjustment of remotely controlled equipment, all equipment should be first disconnected from the WI-I/O 9-x module during these adjustments. Equipment should carry clear markings to indicate remote or automatic operation. E.g. "This equipment is remotely controlled and may start without warning. Isolate at the switchboard before attempting adjustments."

5. The WI-GTWY-9-xxx module is not suitable for use in explosive environments without

additional protection.

WI-GTWY-9-xxx Wireless Gateway Introduction v1.18

How to Use This Manual

To receive the maximum benefit from your WI-GTWY-9-xxx product, please read the Introduction, Installation and Operation chapters of this manual thoroughly before using the WI-GTWY-9-xxx.

Chapter Four Configuration explains how to configure the modules using the Configuration Software available.

Chapter Six Troubleshooting will help if your system has problems. The foldout sheet WI-GTWY-9-xxx Installation Guide is an installation drawing appropriate for

most applications.

CONTENTS

CHAPTER 1 INTRODUCTION 9

1.1 OVERVIEW 9

1.1.1 Modbus / DF1 WI-GTWY-9-MD1 10

1.1.2 Profibus WI-GTWY-9-PRx 11

1.1.3 Ethernet WI-GTWY-9-ET1 12

1.1.4 DeviceNet WI-GTWY-9-DE1 12

1.1.5 Modbus Plus WI-GTWY-9-M+1 13

1.2 THE WI-GTWY-9-XXX STRUCTURE 13

1.2.1 On-board I/O 14

1.3 THE WIRELESS NETWORK 15

1.3.1 WI-I/O 9-x to WI-GTWY-9-xxx Network 15

1.3.2 WI-GTWY-9-xxx to WI-GTWY-9-xxx Network 16

1.3.3 “Data Concentrator” Networks 17

1.3.4 WI-GTWY-9-xxx Repeaters 18

CHAPTER 2 OPERATION 19

2.1 START-UP 19

2.2 OPERATION 19

2.3 DATABASE 22

2.4 THE HOST - WI-GTWY-9-XXX LINK 24

2.4.1 Modbus / DF1 24

2.4.2 Profibus 24

2.4.3 Ethernet 24

2.5 RADIO SYSTEM DESIGN 25

2.5.1 Radio Signal Strength 25

2.5.2 Repeaters 26

2.6 RADIO COMMS FAILURE 26

2.6.1 Monitoring Communications Failure 27

2.7 SECURITY CONSIDERATIONS 27

CHAPTER 3 INSTALLATION 29

3.1 GENERAL 29

3.2 ANTENNA INSTALLATION 29

3.2.1 Dipole and Collinear antennas. 31

3.2.2 Yagi antennas. 32

WI-GTWY-9-xxx Wireless Gateway User Manual V1.18

3.3 POWER SUPPLY 32

3.3.1 AC Supply 33

3.3.2 DC Supply 33

3.3.3 Solar Supply 34

3.4 INPUT / OUTPUT 35

3.4.1 Digital Inputs / Outputs 35

3.5 SERIAL PORT 36

3.5.1 RS232 Serial Port 36

3.5.2 RS485 Serial Port 37

3.6 PROFIBUS PORT 38

3.7 ETHERNET PORT 39

3.8 MODBUS PLUS PORT 40

3.9 DEVICENET PORT 41

CHAPTER 4 CONFIGURATION 42

4.1 INTRODUCTION 42

4.2 CONFIGURATION PROGRAM 43

4.2.1 Program Operation 44

4.2.2 Security 47

4.3 UPLOADING AND DOWNLOADING 49

4.3.1 Loading from a WI-GTWY-9-xxx 50

4.4 MAPPINGS WI-GTWY-9-XXX TO WI-I/O 9-X I/O MODULES 51

4.4.1 Mappings from Inputs at Remote WI-I/O 9-x I/O Modules 51

4.4.2 Mappings from WI-GTWY-9-xxx to Outputs at Remote WI-I/O 9-x I/O Modules 52

4.4.3 Don’t Send if in Comm Fail 54

4.4.4 Startup Polls 55

4.4.5 Polls to Remote Modules 55

4.5 MAPPINGS FROM WI-GTWY-9-XXX TO OTHER WI-GTWY-9-XXX MODULES 55

4.5.1 Entering a Block Mapping 57

4.5.2 Host Device Trigger 58

4.5.3 Time Period 59

4.5.4 Real-Time 60

4.5.5 Change-of-State 62

4.5.6 Block Read Mappings 62

4.5.7 Mixing Normal Mappings and Block Mappings 63

4.5.8 Block mapping to Internal I/O registers 63

4.5.9 Comms Fail for Block Mappings 64

4.5.10 “Repeater-only” Configuration 64

4.6 CHANGE SENSITIVITY & I/O VALUE SCALING 65

4.6.1 Change Sensitivity 65

4.6.2 I/O Value Scaling 66

4.6.3 Unit Details 69

4.6.4 Number of TX only transmissions 69

4.6.5 Reset on Buffer Empty (Firmware version 1.83 and later) 69

4.7 SERIAL CONFIGURATION - MODBUS 70

4.7.1 MODBUS Slave 70

4.7.2 MODBUS Master 72

4.8 SERIAL CONFIGURATION - DF1 75

4.9 FIELDBUS CONFIGURATION 80

4.9.1 Fieldbus Mappings 81

4.10 FIELDBUS CONFIGURATION - PROFIBUS SLAVE 87

WI-GTWY-9-xxx Wireless Gateway Introduction v1.18

4.11 FIELDBUS CONFIGURATION - PROFIBUS MASTER 88

4.11.1 GSD File 88

4.11.2 Protocol and Supported Functions 88

4.11.3 Configuration 88

4.11.4 Configuration Example 96

4.11.5 Message Interface 99

4.11.6 DP Return Codes 119

4.12 FIELDBUS CONFIGURATION - ETHERNET 122

4.12.1 Setting IP Address 122

4.12.2 Modbus TCP 124

4.12.3 EtherNet/IP 127

4.13 FIELDBUS CONFIGURATION – DEVICENET 131

4.13.1 DeviceNet Introduction 131

4.13.2 DeviceNet Address Setting 131

4.13.3 EDS File 131

4.13.4 Protocol and Supported Functions 132

4.14 FIELDBUS CONFIGURATION – MODBUS PLUS 132

4.14.1 Modbus Plus Introduction 132

4.14.2 Modbus Plus Addressing 133

4.14.3 Protocol & Supported Functions 133

4.14.4 Configuration 134

4.15 CONNECTING WI-I/O-EX-1-S-1X SERIAL I/O 135

4.16 ACCESS TO MESSAGE BUFFER COUNT 137

CHAPTER 5 SPECIFICATIONS 138 CHAPTER 6 DIAGNOSTICS 141

6.1 DIAGNOSTICS CHART 141

6.2 DIAGNOSTICS MENU 141

6.3 ETHERNET DIAGNOSTICS 148

6.4 FIELDBUS INDICATING LEDS 150

6.4.1 Ethernet Indicating LED’s 150

6.4.2 Profibus Slave Indicating LED’s 151

6.4.3 Profibus Master Indicating LED’s 152

6.4.4 Modbus Indicating LED’s 153

6.4.5 DeviceNet Indicating LED’s 154

6.5 RADIO PATH TESTING 154

6.6 COMMS LOGGING 156

CHAPTER 7 WARRANTY 160 APPENDIX 1 STATUS REGISTERS 161 APPENDIX 2 IT FUNCTIONALITY 163

WI-GTWY-9-xxx Wireless Gateway User Manual V1.18

Chapter 1 INTRODUCTION

1.1 Overview

The Wireless Gateway products provide a wireless interface between various fieldbus protocols used in process and automation applications. The WI-GTWY-9-xxx includes an integral 900MHz license-free radio transceiver, and transfers transducer and control signals (I/O) using a highly secure and highly reliable radio protocol. The 105U-G units provide the same functionality as the WI-GTWY-9-xxx, but with a fixed frequency radio suitable for licensed frequencies in the 380 – 520 MHz radio band.

Functionality discussed in this manual for the WI-GTWY-9-xxx range also applies to the 105UG range.

The WI-I/O 9-x radio protocol is designed for very efficient radio band usage, with event reporting communications, automatic acknowledgment and error-correction, peer to peer addressing, multiple path routing, and frequency encoding and data encryption for system security.

WI-GTWY

Profibus Ethernet

Modbus DF1 Internet

Profibus

WI-GTWY

WI-I/O 9

Direct I/O

WI-I/O 9

WI-GTWY

Direct I/O

Ethernet

Modbus

WI-GTWY

Profibus

WI-GTWY

WI-I/O 9

Direct I/O

Profibus

Ethernet

Application types include:

Modbus

• The WI-GTWY-9-xxx interfaces between WI-

WI-GTWY

I/O 9-x wireless I/O and various fieldbus protocols. Connect wireless I/O to PLC’s, DCS, SCADA or Internet.

Direct I/O

WI-I/O 9

• Wireless extension of factory automation buses such as Profibus.

• Wireless interconnectivity between different fieldbuses - Ethernet to Profibus to Modbus to

DF1.

WI-GTWY-9-xxx Wireless Gateway Introduction v1.18

• Combined networks of the above.

The WI-GTWY-9-xxx has eight on-board discrete I/O. Each I/O point can be configured individually as a contact input signal, or a discrete output signal. Input signals can be sent via its fieldbus connection to a host device (PLC, DCS etc) or be transmitted by radio to other WI-I/O 9-x units. The output signals can be driven by a host device, or linked to inputs on remote WII/O 9-x units.

This document assumes the reader is familiar with the operation of the WI-I/O 9-x I/O modules for further information, please refer to the User Manuals for these products.

Ordering information:

WI-GTWY-9-MD1 Modbus Master & Slave / DF1 interface WI-GTWY-9-PR1 Profibus-DP Slave interface WI-GTWY-9-PR2 Profibus-DP Master interface WI-GTWY-9-ET1 Ethernet interface - Modbus TCP, Ethernet IP, FTP, HTML, Email WI-GTWY-9-DE1 DeviceNet Slave interface WI-GTWY-9-M+1 Modbus Plus Slave interface The same ordering codes apply to the WI-GTWY-1 product range.

1.1.1 Modbus / DF1 WI-GTWY-9-MD1

The WI-GTWY-9-MD1 can be configured for Modbus master interface, Modbus slave, or DF1. Modbus is a Master-Slave protocol originally developed by Modicon (now part of the Schneider

group). It became a popular interconnect protocol with many equipment manufacturers. One Modbus master controls the Modbus network communications, which can comprise up to 250 Modbus slave devices. The Modbus master can read or write I/O values to/from Modbus slaves. The WI-GTWY-9-MD1 can be configured as either Modbus Master or Modbus Slave. The variation of Modbus supported by the WI-GTWY-9-MD1 is “Modbus RTU” (also known as “Modbus binary”).

DF1 is an Allen-Bradley protocol (Allen-Bradley is now part of the Rockwell Automation group). DF1 offers both full-duplex (point to point) and half-duplex (multidrop) operation. The WI-GTWY-9-MD1 only supports the full-duplex operation - this is the default DF1 mode on most equipment. DF1 full-duplex is a “peer-to-peer” protocol. Either DF1 device can initiate commands to the other device, and both devices will respond to commands from the other device.

The WI-GTWY-9-MD1 has two serial connections - RS232 and RS485, on the bottom end plate of the module. The serial port provides both RS232 and RS485 hardware connections, however both connections are paralleled internally - both connections cannot be used at the same time. Either RS232 or RS485 can be used for Modbus communications, however only the RS232 port can be used for DF1. The serial port must be configured to suit the host device. Serial data rates between 1200 and 19200 baud may be selected, and character types with 7 or 8 data bits, even/odd/none parity, and 1 or 2 stop bits may be selected.

WI-GTWY-9-xxx Wireless Gateway User Manual V1.18

The Modbus/DF1 WI-GTWY-9-MD1 has 4300 general-purpose I/O registers. Each discrete, analog and pulse I/O point takes up one register.

1.1.2 Profibus WI-GTWY-9-PRx

The Profibus WI-GTWY-9-PR1 provides Profibus-DP Slave functionality according to EN

50170. Profibus is a popular automation fieldbus that originated in Germany and is used

extensively by Siemens and other automation suppliers. The Profibus connection on the WI-GTWY-9-PRx is optically isolated RS485 using an on-board

DC/DC converter. The Profibus port has automatic baudrate detection (9600 bit/s - 12 Mbit/s). The Profibus Slave WI-GTWY-9-PR1 will connect to a Profibus LAN controlled by an external

master device. The Profibus Master WI-GTWY-9-PR2 will control communications on a Profibus LAN, and can connect to up to 125 Profibus slave devices.

The Profibus WI-GTWY-9-PR2 I/O database has 4300 registers (each of 16 bit value), however the Profibus interface limits the amount of I/O that can be transferred via the Profibus port.

Slave unit (PR1). The PR1 slave unit only supports 416 x 8 bit bytes of I/O. Of the 416 bytes of I/O, there is a maximum 244 input bytes and maximum 244 output bytes - that is, if 244 input bytes are used then only 172 output bytes can be used (416 – 244). Each byte can represent 8 discrete inputs or outputs, or an 8-bit value, or two bytes can represent a 16-bit value. That is, analog or pulse I/O can be transferred as 8-bit registers (1 byte) or 16-bit registers (2 consecutive bytes).

An “output” is a value coming into the WI-GTWY-9-PR1 via the fieldbus (that is, a value written to the WI-GTWY-9-PR1 from the Profibus master). An input is a value going out from the WI-GTWY-9-PR2 via the fieldbus (a value read by the Profibus master).

So a Profibus Slave WI-GTWY-9-PR1 could handle up to 1952 (244 x 8) discrete inputs or 244 low resolution analog inputs or 122 (244 x ½) high resolution analog inputs, or some combination in between.

For example, a Profibus WI-GTWY-9-PR1 can handle 400 discrete inputs, 240 discrete outputs, 90 analog inputs and 60 analog outputs (assume analogs are 16-bit). The number of input bytes is 230 (400/8 + 90*2). The number of output bytes is 150 (240/8 + 60*2). The total number of I/O bytes is 380. If the number of analog outputs was increased to 90, then the total output bytes would be 210 (240/8 + 90*2), and the total number of I/O bytes is 440 - this exceeds the capacity of the Profibus interface.

Master unit (PR2). The Profibus master interface supports 2048 input bytes and 2048 output bytes. Each byte can be 8 discrete inputs or outputs, but analog or pulse I/O take up 1 byte for low resolution values (8-bit) or 2 bytes for high resolution values (16-bit).

So a Profibus Master WI-GTWY-9-PR2 can handle up to 4300 I/O total, but analog or pulse inputs are limited to 2048 x 8-bit values or 1024 x 16-bit values. The same limit applies to outputs.

For example, a Profibus Master WI-GTWY-9-PR2 can handle 2000 discrete inputs and 500 analog inputs (assume analogs are 16-bit). The number of input bytes is 1250 (2000/8 + 500*2). The same unit could handle 4000 discrete outputs and 750 analog outputs. The number of output

WI-GTWY-9-xxx Wireless Gateway Introduction v1.18

bytes is 2000 (4000/8 + 750*2). The total number of I/O is 3250 which is less than the total limit of 4300.

1.1.3 Ethernet WI-GTWY-9-ET1

The Ethernet WI-GTWY-9-ET1 provides several different types of Ethernet functionality: ♦ Modbus TCP. Modbus TCP uses Modbus as a base protocol within an Ethernet

communications structure. The WI-GTWY-9-xxx provides class 0, 1 and partially class 2 slave functionality.

♦ EtherNet IP. EtherNet IP is the version of Ethernet used by Allen-Bradley devices. The WI-

GTWY-9-ET1 provides level 2 I/O server CIP (ControlNet and DeviceNet).

♦ Internet functionality. The WI-GTWY-9-ET1 has 1.4Mbyte of non-volatile “flash” memory

for embedded web “pages” (dynamic HTTP), on-board file system, user downloadable web

pages through FTP server, and email functionality (SMTP). The Ethernet connection is a transformer isolated RJ45 connector, 10/100 Mbit/sec. The Ethernet WI-GTWY-9-ET1 I/O database has 4300 registers (each of 16 bit value), however

the Ethernet interface only supports 2048 input bytes and maximum 2048 output bytes. Each byte can be 8 discrete inputs or outputs, but analog or pulse I/O take up 1 byte for low resolution values (8-bit) or 2 bytes for high resolution values (16-bit).

An “output” is a value coming into the WI-GTWY-9-ET1 via the fieldbus. An input is a value going out from the WI-GTWY-9-ET1 via the fieldbus.

So an Ethernet WI-GTWY-9-ET1 can handle up to 4300 I/O total, but analog or pulse inputs are limited to 2048 x 8-bit values or 1024 x 16-bit values. The same limit applies to outputs.

For example, an Ethernet WI-GTWY-9-ET1 can handle 2000 discrete inputs and 500 analog inputs (assume analogs are 16-bit). The number of input bytes is 1250 (2000/8 + 500*2). The same unit could handle 4000 discrete outputs and 750 analog outputs. The number of output bytes is 2000 (4000/8 + 750*2). The total number of I/O is 3250 which is less than the total limit of 4300.

1.1.4 DeviceNet WI-GTWY-9-DE1

The DeviceNet WI-GTWY-9-DE1 provides DeviceNet 2.0 Slave functionality. DeviceNet is an automation fieldbus developed by Allen-Bradley (Rockwell Automation).

The DeviceNet connection on the WI-GTWY-9-DE1 is optically isolated RS422 with selectable baudrate between 125 and 500 Kbit/sec.

The WI-GTWY-9-DE1 I/O database has 4300 registers (each of 16 bit value), however the DeviceNet interface only supports 512 x 8 bit input bytes and 512 x 8 bit output bytes, and this limits the amount of I/O that can be transferred via the DeviceNet port.

Each byte can represent 8 discrete inputs or outputs, or an 8-bit value, or two bytes can represent a 16-bit value. That is, analog or pulse I/O can be transferred as 8-bit registers (1 byte) or 16-bit registers (2 consecutive bytes).



WI-GTWY-9-xxx Wireless Gateway User Manual V1.18

An “output” is a value coming into the WI-GTWY-9-DE1 via the fieldbus (that is, a value written to the WI-GTWY-9-DE1 from the DeviceNet master). An input is a value going out

from the WI-GTWY-9-DE1 via the fieldbus (a value read by the DeviceNet master). So a DeviceNet WI-GTWY-9-DE1 can normally handle up to 4096 (512 x 8) discrete inputs or

512 low resolution analog inputs or 256 (512 x ½) high resolution analog inputs, or some combination in between. It can also handle the same number of outputs; however the total I/O count cannot exceed the WI-GTWY-9-DE1 database size of 4300.

1.1.5 Modbus Plus WI-GTWY-9-M+1

The Modbus Plus WI-GTWY-9-M+1 provides Modbus Plus Slave functionality. The Modbus Plus connection on the WI-GTWY-9-M+1 is optically isolated RS485 with standard baudrate of 1 Mbit/sec.

The WI-GTWY-9-M+1 I/O database has 4300 registers (each of 16 bit value), however the Modbus Plus interface only supports 1024 input registers and maximum 1024 output registers. Each register can be 16 discrete inputs or outputs, or one analog or counter 16-bit value.

An “output” is a value coming into the WI-GTWY-9-M+1 via the fieldbus. An input is a value going out from the WI-GTWY-9-M+1 via the fieldbus.

So an Modbus Plus WI-GTWY-9-M+1 can handle up to 4300 I/O total, but analog or pulse inputs are limited to 1024 x 16-bit values. The same limit applies to outputs.

The Modbus Plus interface allows global data base transactions with routing for up to six Modbus Plus networks.

1.2 The WI-GTWY-9-xxx Structure

The WI-GTWY-9-xxx has three functional sections:

• The Radio Interface consists of an

I/O database (or "Process Image") that maintains the latest values of all I/O in the wireless I/O system. The I/O database comprises 4300 x 16 bit I/O registers and 4300 x 16 bit status registers. There are also other registers in the database that can be used for system management - they are discussed later in this manual. NOTE – the terms ‘Radio Interface’ and ‘I/O database’ are used interchangeably throughout the manual.



                       



     

WI-GTWY-9-xxx

   

     

 

    

      

          

        

   

   

     

• The radio port allows the WI-GTWY-9-xxx to communicate with other WI-GTWY-9-xxx

and/or WI-I/O 9-x modules using the WI-I/O 9-x protocol. Messages from the WI-I/O 9-x modules are received by the radio port and used to update the input values in the WI-GTWY-

WI-GTWY-9-xxx Wireless Gateway Introduction v1.18

9-xxx Radio Interface. The radio port also creates the correct radio message to set outputs on the remote WI-I/O 9-x modules.

The WI-I/O 9-x protocol is an extremely efficient protocol for radio communications. Radio messages can be sent using exception reporting - that is, when there is a change of an input signal - or by read/write messages. Each message can comprise a single I/O value, or multiple I/O values (termed a “block” of I/O). There are also update messages, which are sent for integrity purposes. Messages include error checking, with the destination address sending a return acknowledgment. Up to five attempts are made to transmit the message if an acknowledgment is not received. The WI-I/O 9-x protocol is designed to provide reliable radio communications on an open license-free radio channel.

• The Fieldbus port enables communications between a host device, which could be a PLC,

DCS, HMI, intelligent transducer, etc), and the WI-GTWY-9-xxx Radio Interface database. A “host device” may be one or several devices connected to the same fieldbus or network (for example, an Ethernet LAN) - in this manual, the LAN is considered as a “host device”.

The fieldbus port decodes messages from the host device and reads or writes I/O values to the database. The fieldbus port can also generate messages to the host device.

The WI-GTWY-9-xxx I/O database effectively isolates the fieldbus and the radio network. This provides a high level of system performance. The WI-I/O 9-x radio protocol is very efficient and reliable for radio communications. It minimizes radio channel usage by "change-of-state" reporting, and allows the use of intermediate repeater addresses. It also allows peer-to-peer (WII/O 9-x to WI-I/O 9-x, WI-GTWY-9-xxx to WI-GTWY-9-xxx) and peer-to-master (WI-I/O 9-x to WI-GTWY-9-xxx) communications. PLC protocols, by comparison, are designed to provide transfer of large I/O files by "wire" link. The WI-GTWY-9-xxx retains the advantage of both protocols in their respective communications media.

1.2.1 On-board I/O

The WI-GTWY-9-xxx has eight on-board discrete I/O. Each I/O point can be used as either a discrete input (voltage free contact input) or discrete output (transistor output) - an I/O point cannot be used as both input and output. Each I/O point is linked to two separate I/O registers in the database - one for the “input” function and one for the “output” function.. If the output register is set “on” by the fieldbus or by a radio message from a remote module, then the WIGTWY-9-xxx will automatically set the input register for the same I/O point to “off”. This means that the output register has priority over the input register - if there is a conflict, the input value is ignored.

The WI-GTWY-9-xxx also has three internal inputs linked to I/O registers:

♦ Supply voltage status - if the normal supply fails, this status is set on. ♦ Low battery voltage. The WI-GTWY-9-xxx has an internal battery charger to trickle charge a

back-up battery. If the battery voltage is low, this status is set. ♦ Battery voltage - the actual value of the connected battery voltage.

1.2.2 I/O Expansion - WI-I/O-EX-1-S-xx modules

WI-GTWY-9-xxx Wireless Gateway User Manual V1.18

Where additional discrete or analog I/O is required, an external expansion I/O module can be connected to the RS485 port of the WI-GTWY-9 module. See section 4.15 for more details on

this. Note: Serial Expansion modules can only be used with the WI-GTWY-9-MD1 unit under

certain circumstances.

• WI-GTWY-9-MD1 is configured as “Repeater-only”

• WI-GTWY-9-MD1 is configured as a Modbus Master and WI-I/O-EX serial expansion

modules are used as Modbus Slaves.

WI-I/O 9

The WI-I/O-EX modules have the ability to be configured to communicate the same way as a WII/O-9 module using the WIB-net Protocol or via as a Modbus Slave communicating Modbus RTU

WI-GTWY

WI-I/O 9-K

protocol. They can be setup with an address range of 1-99, which is selectable via the rotary switches on end plate of the module.

WI-I/O 9

WI-I/O-9

1.3 The Wireless Network

The WI-GTWY-9-xxx can communicate with up to 490 other addresses - this could be 490 other WI-I/O 9-x modules, or in the case of WI-I/O 9-K modules, it could be many thousands of modules (as many WI-I/O 9-K modules can share the same address). WI-GTWY-9-xxx modules may take up more than one address under some circumstances.

Any WI-GTWY-9-xxx or WI-I/O 9-x module can act as a radio repeater for other modules - that is, radio messages can be passed onto other modules. Up to five repeater addresses can be configured for messages transmitted to a WI-GTWY-9-xxx module.

Each module can have a unit address between 1 – 95, but the WI-GTWY-9-xxx also recognizes repeater addresses in conjunction with the unit address as the module “identifier”. Hence module #2 is recognized as different to #2 via #57 - #57 being a repeater.

1.3.1 WI-I/O 9-x to WI-GTWY-9-xxx Network

In the wireless I/O system, the WI-GTWY-9-xxx acts as a normal WI-I/O 9-x module (this covers WI-I/O 9-x I/O, WI-I/O-EX-1-S-1x I/O, WI-I/O 9-x-K and WI-I/O 9-x-C modules).

WI-I/O 9-x modules transmit messages to the WI-GTWY-9-xxx address and the WI-GTWY-9xxx acknowledges these messages like a normal WI-I/O 9-x module. When a WI-GTWY-9-xxx transmits messages to change remote outputs, it will "re-try" if it does not receive an acknowledgment, like a normal WI-I/O 9-x module.

Remote WI-I/O 9-x modules can connect to WI-I/O-EX-1-S-1x modules in the normal way. The WI-GTWY-9-xxx host can access I/O on WI-I/O-EX-1-S-1x modules by using the intermediate WI-I/O 9-x as a repeater.

WI-GTWY-9-xxx Wireless Gateway Introduction v1.18

WI-I/O 9-x modules can transmit input messages directly to outputs on other WI-I/O 9-x module, as well as the WI-GTWY-9-xxx. The same input can be transmitted to different addresses by entering two "mapping" configurations at the remote module.

Normal WI-I/O 9-x Messages

I/O registers in a WI-GTWY-9-xxx can be configured (mapped) to outputs at remote WI-I/O 9-x modules, or I/O registers in WI-GTWY-9-xxx modules. The WI-GTWY-9-xxx will transmit an I/O message when a “change-of-state” occurs for that I/O register. Registers have a configurable “sensitivity” value - this determines how much the register value has to change to

WI-I/O 9

trigger a change message. A change-ofstate occurs when the register value has

PLC

changed by more than the sensitivity value since the last transmission.

WI-GTWY

WI-GTW Y

The WI-GTWY-9-xxx also transmits periodic update messages if there has been no change - if an I/O register is

WI-I/O

mapped to a remote output or another WI-GTWY-9-xxx, then that register can be configured with an update time.

WI-GTWY-9-xxx modules can transmit to WI-GTWY-9-xxx modules as well as other WIGTWY-9-xxx modules. There can be multiple WI-GTWY-9-xxx modules in a network - as well as WI-I/O 9-x I/O. Because the WI-I/O 9-x protocol is peer-to-peer, there are few constraints on communications between multiple WI-I/O 9-x modules.

Poll Messages

A WI-GTWY-9-xxx can also generate poll messages to remote WI-I/O 9-x modules. These poll messages act in the same way as a start-up poll - the remote module immediately responds with update messages for any I/O mappings configured to the WI-GTWY-9-xxx.

Poll messages can be triggered by:

♦ time period, configurable 1 – 4096 sec (1.1 hour), or ♦ real time clock, or ♦ on demand by the host device, by writing to a “trigger register” in the WI-GTWY-9-xxx

1.3.2 WI-GTWY-9-xxx to WI-GTWY-9-xxx Network

Different types of WI-GTWY-9-xxx modules can communicate - for example, a Modbus WIGTWY-9-xxx can communicate with an Ethernet WI-GTWY-9-xxx. I/O registers in one WIGTWY-9-xxx can be transmitted to I/O registers in another WI-GTWY-9-xxx. When the WIGTWY-9-xxx is configured, “mappings” can be entered linking I/O registers to registers in another WI-GTWY-9-xxx.

As well as the normal “I/O change” messages and update messages, the WI-GTWY-9-xxx has “block read” and “block write” messages for use with other WI-GTWY-9-xxx modules. These messages will transmit multiple register values instead of only one as in the normal WI-I/O 9-x message. The block read/write messages increase the efficiency of radio communications where a

WI-GTWY-9-xxx Wireless Gateway User Manual V1.18

WI-GTWY-9-xxx “sees” a large number of changes in its database at the one time. For

example, if a host writes a block of 100 signal values to a WI-GTWY-9-xxx, and 20 of these values have changed since the last write-operation. If the block is mapped to another WIGTWY-9-xxx, then the WI-GTWY-9-xxx can transmit all 20 values in one radio message, instead of 20 messages.

Normal I/O messages can be repeated by any type of WI-I/O 9-x I/O module, however block read/write messages can only be repeated by other WI-GTWY-9-xxx modules.

Block Read Message

A block read message is a request to another WI-GTWY-9-xxx to transmit the values of a consecutive block of registers. The destination WI-GTWY-9-xxx will respond with the values, which will be stored in a corresponding block of registers in the originating WI-GTWY-9-xxx. A block read message can be triggered by:

♦ time period, configurable 1 – 4096 sec (1.1 hour), or ♦ real time clock, or ♦ on demand by the host device, by writing to a “trigger register” in the WI-GTWY-9-xxx.

Block Write Message

A block write message transmits a consecutive block of register values from one WI-GTWY-9xxx to a destination WI-GTWY-9-xxx. It can be triggered by:

♦ time period, configurable 1 – 4096 sec (1.1 hour), or ♦ real time clock, or ♦ on demand by the host device, by writing to a “trigger register” in the WI-GTWY-9-xxx, or ♦ a change-of-state event occurring within the block of I/O registers.

If a block write message has been configured to be transmitted on change-of-state, a “time window” is configured. When a change-of-state occurs in one of the registers in the block, the time window will be activated. All changes during the time window will be grouped together and transmitted as one block write message. That is, the block write message will not be sent immediately the first change-of-state occurs (unless the time window is configured to zero), but will be sent at the end of the time window - any other registers in the block that change during the time window will be sent as part of the same message. The time window can be configured from 0 – 255 seconds.

1.3.3 “Data Concentrator” Networks

WI-GTWY-9-xxx units can act as “data concentrator” units to collect I/O from a local network of WI-I/O 9-x wireless I/O modules and pass the I/O on to another WI-GTWY-9-xxx as a block.

This type of network reduces the amount of radio traffic and is suitable for systems with a large number of I/O modules. The system is divided into local sub-networks, each with a WI-GTWY9-xxx unit. The WI-I/O 9-x modules transmit their I/O vlaues to the WI-GTWY-9-xxx. The WIGTWY-9-xxx then transfers these values to the “central” WI-GTWY-9-xxx using a block transfer which is very efficient compared to a lot of individual I/O transmissions.

WI-GTWY-9-xxx Wireless Gateway Introduction v1.18

The data concentrator network is different than using the WI-GTWY-9-xxx as a repeater. A repeater re-transmits each message in the same format. A data concentrator collects the I/O values as a block, and transmits the complete block in one transmission.

1.3.4 WI-GTWY-9-xxx Repeaters

Any WI-I/O 9-x module can repeat a normal radio message, however only WI-GTWY-9-xxx modules can repeat a block message. WI-GTWY-9-xxx units connected to a host device can also act as a repeater for other modules.

Where a WI-GTWY-9-xxx is being used without a host device as a repeater or data-concentrator, it can be configured as “Repeater-only”. This allows the RS232/485 port to be used for on-line diagnostics

NETWORK OF WI-I/O 9-x UNITS

WI-GTWY

TO HOST DEVICE

NETWORK OF WI-I/O 9-x UNITS

WI-GTWY

WI-GTWY-9-xxx Wireless Gateway V1.18

Chapter 2 OPERATION

2.1 Start-up

The WI-GTWY-9-xxx operating software and the database configuration are stored in nonvolatile memory; however the database I/O register values are lost on power failure (in the same way as a PLC).

On start-up, the WI-GTWY-9-xxx sends "start-up poll" messages to remote modules based on the source address of inputs configured in the database (the start-up messages can be disabled by configuration). The remote modules respond with update messages for their inputs, which sets initial values in the WI-GTWY-9-xxx I/O database registers. The WI-GTWY-9-xxx provides a delay of 5 seconds between each start-up poll, to allow the remote module to respond and to avoid overloading the radio channel.

If there are a lot of remote modules, then this start-up stage may take a significant time, and this should be allowed for in the system design. The WI-GTWY-9-xxx has an internal battery charger feature and the use of a back-up battery should be considered if this start-up delay presents a constraint to system reliability. Start-up polls may be disabled for individual remote modules in the database configuration.

For the host device, the WI-GTWY-9-xxx provides an "Active" signal on the RS232 port (DCD pin 1). Its purpose is to indicate to the host that the WI-GTWY-9-xxx is now processing output messages for the remote modules. When the WI-GTWY-9-xxx powers down (or should an internal fault occur), the "Active" signal resets (turn “off” or “0”). When the WI-GTWY-9-xxx starts-up, it holds the "Active" signal in a reset condition (“off” or “0”) for a time equal to the number of remote addresses (or modules) configured times 5 seconds plus any delay if remote addresses are offline. For example, if there are 20 remote addresses configured in the WIGTWY-9-xxx database, then the “active” signal will be held in the reset state for 100 seconds (20 x 5). During this period, the WI-GTWY-9-xxx will not change any output values in its database. After this time, the WI-GTWY-9-xxx will set the "Active" signal (to “on” or “1”) - the host can then send messages to the WI-GTWY-9-xxx to update the output values in the database.

2.2 Operation

The WI-GTWY-9-xxx database can hold values for 4300 I/O signals plus the 8 on-board I/O. The database registers (also called I/O registers) can be accessed by both the radio port and the fieldbus port. The host device can change values in the database via the fieldbus, and the WIGTWY-9-xxx can transmit radio messages out with the new values. Radio messages can be received with new values for database registers, and these new values can be written to the host device or read by the host device, via the fieldbus.

The WI-GTWY-9-xxx operation must be configured before the WI-GTWY-9-xxx will function. Configuration is achieved by creating a configuration file on a PC and downloading this file to the WI-GTWY-9-xxx. The WI-GTWY-9-xxx configuration may also be "uploaded" to a PC for

WI-GTWY-9-xxx Wireless Gateway V1.18

viewing and modification. For more information, refer to the Configuration section of this document.

Each I/O register in the WI-GTWY-9-xxx database has a 16-bit value. It doesn’t matter if the remote I/O is digital (discrete), analog or pulse. The host protocol driver in the WI-GTWY-9xxx will convert the 16 bit value into a value that the host will understand. For example, if the host device requests a binary/digital read command, the WI-GTWY-9-xxx will convert the 16 bit value into a binary (1 bit) value before it responds.

The WI-GTWY-9-xxx is able to scale the I/O value between the I/O database and the host device

- this is a user-configurable function.

#14

DIN1

WI-I/O 9-x-1

WI-GTWY-9

An example of normal operation - assume that a remote module has address 14 and the WIGTWY-9-xxx is address 1. Module #14 is configured with a mapping DI1 → I/O Reg 76 at #1. When DI1 turns "on", module #14 transmits a message. If the WI-GTWY-9-xxx can hear this message, it will transmit an acknowledgment back to module #14, and updates the value of I/O register 76 in the WI-GTWY-9-xxx database. The host device can read I/O register 76 via the data-bus, or the WI-GTWY-9-xxx may write the value of I/O register 76 to the host device.

I/O registers that receive values from other WI-I/O 9-x or G modules via radio are configured with a “Communications fail time”. If the WI-GTWY-9-xxx does not receive a message for this I/O register within the comms-fail time, then the I/O register is given a “comms fail” status which the host device can read. The I/O value can also be configured to reset to zero on commsfail.

I/O registers that transmit out to other WI-I/O 9-x or WI-GTWY-9xxx modules are configured with an “update time” and a “sensitivity”. The WI-GTWY-9-xxx will transmit a message to the configured remote output whenever the I/O register value changes by the sensitivity amount – if it has not changed within the update time, the WI-GTWY-9-xxx will send a message anyway. The WI-GTWY-9-xxx will make five attempts to send a message - if it does not receive an acknowledgment from the remote module, then the I/O register is given a “comms fail” status which the host device can read.

Each I/O register has an associated “status” register, which includes information such as commsfail status. As well as each I/O register having an individual comms-fail status, each remote module has an overall comms fail status. This status is “set” (on) whenever a comms-fail occurs for an individual I/O register, and is “reset” (off) whenever a message is received from the remote module. The WI-GTWY-9-xxx can be configured to not send any update messages to a remote module if it senses that the remote module is in “comms fail” - that is, if any I/O register associated with the remote module is in “comms fail”. It will start sending update messages

WI-GTWY-9-xxx Wireless Gateway V1.18

again when the WI-GTWY-9-xxx receives a message from the remote module. The default

configuration is that output updates ARE sent during comms fail conditions.

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2.3 Database

The WI-GTWY-9-xxx database (Radio Interface) has 10 000 registers, each of 16 bit size. The structure of the database is:

Registers Purpose

0 - 4299 I/O registers 4300 - 4399 On-board I/O 4401 - 4499 Comms-fail status and radio strengths for remote modules 5000 - 9499 Status registers - 16 bit status for each I/O signal 9500 - 9999 Status registers for block read/write messages

The register numbers may be used by the Host Protocol Driver to access I/O values and I/O status information. Each configured I/O point has a 16 bit value (in registers 0000 - 4299), and a 16 bit status value. The status register is located at 5000 plus the I/O value register. For example, an I/O point in register number 2560 has a status value in register number 7560 (5000 + 2560).

Details of the status register are provided in Appendix A. The most important part of the status register is the 15th or most significant bit - this indicates comm-fail status for the I/O register. If the most significant bit is set, then the I/O register is in comms-fail.

The host device can read the status registers. For example, the communications status of an output configured at register number 3001 can be examined by reading register number 8001 (5000 + 3001). If the register value is greater than 32767, then the 15th bit is set, indicating that the output has a communications failure.

2.3.1 On-board I/O and Internal I/O

The WI-GTWY-9-xxx has eight discrete I/O points. These may be used as inputs or as outputs. Inputs are linked to registers 4300-4307. That is, if a contact connected to DIO1 is “on”, then register 4300 is given an “on” value. The inverse of the input values are stored in registers 4370-

4377. Outputs are controlled from registers 4320-4327; that is, if register 4327 is set to an “on” value,

then output DIO8 is activated. Whenever an output register is set “on”, the corresponding input register is automatically set

“off”. For example, if register 4321 is set to “1”, the WI-GTWY-9-xxx will also set 4301 to “0”. This means that if both the input and output registers corresponding to the same I/O point are used in the configuration, then the output register has priority.

Outputs may be written to by either the host device or by a remote WI-I/O 9-x via the radio port. Input values can be sent to the host device or to a remote module via the radio port.

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The WI-GTWY-9-xxx also monitors its battery voltage and supply voltage. These are stored in registers 4310 and 4311 respectively, as 16 bit values, scaled so that a value of 16384 decimal

(hex 4000) corresponds to 8 V, and a value of 49152 (hex C000) corresponds to 40V. A low battery alarm is available at register 4308. This becomes active when the battery voltage

falls below 11.3V, and clears when the battery voltage rises above 11.8V. Supply voltage is also monitored, and an alarm is available at register 4309. This becomes active if the supply voltage falls below 8.0V, and clears when the supply voltage rises above 9.0V.

I/O Register Description I/O Register Description

4300 Input value DIO 1 4320 Output value DIO 1 4301 Input value DIO 2 4321 Output value DIO 2 4302 Input value DIO 3 4322 Output value DIO 3 4303 Input value DIO 4 4323 Output value DIO 4 4304 Input value DIO 5 4324 Output value DIO 5 4305 Input value DIO 6 4325 Output value DIO 6 4306 Input value DIO 7 4326 Output value DIO 7 4307 Input value DIO 8 4327 Output value DIO 8 4308 Low battery voltage status 4309 Supply voltage fail status 4310 Battery voltage value 4311 Supply voltage value 4370 - 4379 Inverse values of

4300 - 4309

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“HOST DEVICE”

2.4 The Host - WI-GTWY-9-xxx Link

For the host device, the WI-GTWY-9-xxx "looks" like a single device (or a "virtual PLC"), containing the I/O for the complete wireless I/O system.

2.4.1 Modbus / DF1

The user selects whether the WI-

DATA-BUS

DATABASE

I/O

"VIRTUAL PLC"

GTWY-9-MD1 should act as a Modbus Master or Modbus Slave or DF1 device.

The data type and baud rate of the serial communications must be configured at the WI-GTWY9-xxx to match the host. Data types can be 7 or 8 bit, even/odd/no parity, with 1 or 2 stop bits. Data rates can be 300 - 19200 baud.

The full WI-GTWY-9-xxx database (4300 registers) can be accessed by the Host Device.

2.4.2 Profibus

The Profibus port has auto-detect of baud rate from 9600 bits/sec to 12Mbit/sec - no configuration is required.

The Profibus units have internal hardware comprising the Profibus Interface. The Profibus Interface handles all Profibus DP Network communications. The internal Radio Interface is separate to the Profibus Interface, and handles all radio communications. I/O in the Radio Interface is linked to I/O in the Profibus Interface in a flexible way via WI Series Configuration Software.

The Profibus Slave interface provides a total of 416 I/O bytes, with a maximum 244 input bytes and maximum 244 output bytes. A Profibus byte can contain 8 discrete (binary) values, or two bytes can be used for a 16-bit analogue or pulse register. So the Profibus interface is limited to 1952 discrete inputs or 122 analogue inputs or a combination. The same applies for outputs.

For example, a Profibus host wants to read 800 discrete inputs (100 bytes) and write 400 discrete outputs (50 bytes). This will take up 150 bytes of the Profibus Interface, leaving 266 left. The remaining bytes could be used for 133 analogue I/O - up to 72 analogue inputs (244 – 100 discrete input bytes) plus 61 analogue outputs - or vice-versa.

The Profibus Master interface provides a total of 2048 input bytes and 2048 output bytes. A byte can contain 8 discrete (binary) values, or two bytes can be used for a 16-bit analogue or pulse register. So the interface is limited to 4300 discrete inputs (the limit of the WI-GTWY-9xxx database) or 1024 analogue inputs (the limit of the HMS interface) or a combination. The same applies for outputs.

2.4.3 Ethernet

The Ethernet port automatically handles Ethernet communications at 10 or 100 Mbit/sec. An IP address is entered so that other Ethernet devices can recognize the WI-GTWY-9-xxx.

The Ethernet units have internal hardware comprising the Ethernet Interface. The Ethernet Interface handles all Ethernet Network communications. The internal Radio Interface is separate

WI-GTWY-9-xxx Wireless Gateway V1.18

to the Ethernet Interface, and handles all radio communications. I/O in the Radio Interface is linked to I/O in the Ethernet Interface in a flexible way via WI Series Configuration Software.

The Ethernet Interface provides a total of 2048 input bytes and 2048 output bytes. An Ethernet byte can contain 8 discrete (binary) values, or two bytes can be used for a 16-bit analog or pulse register. So the Ethernet Interface is limited to 4300 discrete inputs (the limit of the WI-GTWY9-xxx database) or 1024 analog inputs (the limit of the Ethernet interface) or a combination. The same applies for outputs.

For example, an Ethernet host wants to read 500 analog inputs (1000 bytes). The remaining input bytes (1548) could be used for 12,384 discrete inputs - but the WI-GTWY-9-xxx database is not this big. Provided there are no outputs required, there could be 3800 discrete inputs (4300 – 500 analogs). If there are outputs required, then the number of discrete inputs available will be further limited.

2.5 Radio System Design

Each wireless I/O system can have up to 95 unit addresses, although up to 255 WI-I/O 9-K module can share the same unit address (refer to WI-I/O 9-K User Manual).

Each WI-I/O 9-x module can have up to 31 x WI-I/O-EX-1-S-1x modules connected to it. These modules are addressed 96 - 127. More than one WI-I/O-EX-1-S-1x module can have the same address, provided they are not connected to the same WI-I/O 9-x module - that is, #100 via #16 is identified as a different module to #100 via #65.

A constraint that needs to be considered is the capacity of the radio channel. If there is too much traffic on the radio channel, then the system quickly becomes unreliable. The recommended maximum average traffic density is 100 messages per minute provided all radio paths are reliable. If there are marginal radio paths, resulting in re-tries of transmitted messages, then the maximum traffic density is reduced considerably. Each block read/write messages should be counted as two messages because of the length of these messages.

A WI-GTWY-9-xxx can be used as a repeater module for messages between other modules.

2.5.1 Radio Signal Strength

The WI-GTWY-9-xxx records the radio signal strength of remote modules that communicate directly (that is, not via repeaters). There are 95 database registers (4401 – 4495) which store the radio strengths – corresponding to remote addresses #1 - #95. The radio strength (RSSI) is measured in dBm (relative to 1mW of RF power). The RSSI value is stored in the 8 least significant bits of each register - a value of –84 dBm would be stored as decimal 84.

These database registers will hold the strength of the last message received from the address. If a message is received from a remote module via a repeater, then the measurement is recorded in the address of the last repeater. For example, if a message is received from #24 directly, then the RSSI will be recorded in register 4424. If a message is received from #24 via #25, then the RSSI is recorded in register 4425. The WI-GTWY-9-xxx will not know what the radio strength of the message from #24 to #25 is. If #25 is another WI-GTWY-9-xxx, then it can record this RSSI and this register could be mapped to an I/O register in the first WI-GTWY-9-xxx.

WI-GTWY-9-xxx Wireless Gateway V1.18

The RSSI registers can be read by the host device, or mapped to I/O registers in other WIGTWY-9-xxx modules.

The first half of the register (8 most significant bits) will be decimal 0 (hex 00) if the remote module has active communications. If a comms fail status to this address occurs, the most significant bit will be set. For example, if the last message received from #38 is –99dBm, then the 16 bit value of register 4438 will be decimal 99 or hex 0063. If the “comms fail” status for #38 is set, the 16 bit value of register 4438 will become decimal 32,867 (32768 + 99) or hex

8063.

2.5.2 Repeaters

Radio paths may be extended by using intermediate modules as repeaters. A repeater will receive and re-transmit the radio message. Up to five repeater addresses can be configured - that is, a radio message can pass through five intermediate modules. For normal I/O messages, any WI-I/O 9-x module (except WI-I/O 9-x-K modules) can be used as a repeater, however for block read/write messages, only WI-GTWY-9-xxx modules can act as repeaters.

2.6 Radio Comms Failure

The WI-GTWY-9-xxx has an internal "communications failure" (comms fail) status for each I/O point in its database. There is also a comms fail status for each module with direct communications - see 2.5.1 above.

For I/O registers which are mapped to a remote output or another WI-GTWY-9-xxx, the comms fail status is set if the WI-GTWY-9-xxx does not receive an acknowledgment for a message being sent to that remote output. The comms fail status resets when a successful transmission occurs.

For I/O registers which have been mapped , from a remote input or another WI-GTWY-9-xxx, a comms fail time period may be configured. If a radio message for this I/O register has not been received within this time, then this registers comms fail status is set. The comms fail status will reset when a message is received for this register. If the comms fail time is configured as zero, then the comms fail status will never be activated. Registers can be configured to reset (go back to a value of zero) on comms fail.

The communications failure status is bit 15 of the status register for each I/O point. If the host device reads a register as a digital or binary value, then the WI-GTWY-9-xxx returns bit 15 of the register (0 or 1) - this is the comms fail bit of a status register.

It is important to use the comms fail status in the overall system design, as any system can fail. The WI-GTWY-9-xxx also provides an additional comms failure feature to stop the WI-GTWY-

9-xxx transmitting output messages to an individual remote address if the WI-GTWY-9-xxx already knows that this remote address is in communication failure. This prevents the WIGTWY-9-xxx from congesting the radio channel with a lot of unnecessary transmissions (and retransmissions). This function is called "Don’t Send if In Comm Fail" and is configurable by the user for each individual remote address. The WI-GTWY-9-xxx retains a "remote address comms fail" status for the remote addresses configured for this function. If any output with this remote

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address goes into communications failure, then the remote address comms fail status is set ("on"

or 1) - every time an input with this remote address receives a radio message, then the remote address comms fail status is reset ("off" or 0). While the remote address comms fail status is set, the WI-GTWY-9-xxx disables any output messages being sent to this remote address.

When this feature is configured, all output transmissions are stopped if communications with a remote module fails for a short period. They will start again when an input message from this module is received. If the WI-GTWY-9-xxx determines that a output message should be sent to an output which is disabled because of this feature, then the output message will not be sent and the comms fail status of that output is set ("on" or 1).

If it is desired to use this function with a remote WI-I/O 9-x module, but there are no inputs from this module being used, then it is easy to configure an unused input or an internal input (mains fail or low battery voltage etc). It is the comms fail status for the input, which is used, not the input itself.

2.6.1 Monitoring Communications Failure

The host device can monitor the communications status of an I/O point by reading the status register for this point as a binary/discrete register. Modbus, and many other protocols, will convert a 16 bit register value to a binary/discrete value by returning the most significant bit - for the status register, this corresponds to the comms status bit.

For example, to monitor the comms status of I/O register 1045, perform a binary/discrete read on register 6045 (the status register for 1045). A value of “1” will be returned if this I/O point is in comms fail, and a “0” returned if the status is normal.

If it is desired to monitor the comms status of all I/O points, it is more efficient to only monitor the comms status of one I/O point at each remote module (if this point is in comms fail, then all points at the remote module will be in comms fail). If this point is an input, then the comms fail time for this input can be made short, to give an early warning of a comms problem (this means that the corresponding update time for the input at the WI-I/O 9-x will need to be short). If the point is an output, then the update time for the output should be made short.

2.7 Security Considerations

There are three dimensions of security considerations:

1. Failure to operate when required - or “operational reliability”.

The features discussed above optimize operating reliability. Using an acknowledgment and re-try protocol ensures that the transmitting module is aware whether the transmitted message has been transmitted reliably. The “comms fail” alarms provide indication if the radio link has failed to operate.

2. Mal-operation, or operating when not requested.

This problem occurs when an output is “triggered” by the wrong radio device. The WIGTWY-9-xxx modules use frequency encoding and a very secure addressing system to

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ensure this does not occur. An additional security level using data encryption can also be selected.

3. Malicious operation, or “hacking”

This is the problem most associated with security concerns - the ability for someone to access information from a radio system by “listening-in”, or to cause damage by transmitting radio messages to force outputs.

A security option can be selected during the module configuration to protect against this. The security option (if selected) adds data encryption to radio messages. Modules in the same system are automatically configured with the encryption key, such that only these modules can understand each other. “Foreign” modules will hear the messages, but cannot decrypt the messages. For more information, refer to section 4.2.2.

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Chapter 3 INSTALLATION

3.1 General

The WI-GTWY-9-xxx module is housed in a rugged aluminum case, suitable for DIN-rail mounting. Terminals will accept wires up to 12 gauge (2.5 sqmm) in size.

All connections to the module must be low voltage (SELV). Normal 110-240V mains supply should not be connected to any terminal of the WI-GTWY-9-xxx module. Refer to Section

3.3 Power Supply. Before installing a new system, it is preferable to bench test the complete system. Configuration

problems are easier to recognize when the system units are adjacent. Following installation, the most common problem is poor communications caused by incorrectly installed aerials, or radio interference on the same channel, or the radio path being inadequate. If the radio path is a problem (i.e. path too long, or obstructions in the way), then higher performance aerials or a higher mounting point for the aerial may rectify the problem. Alternately, use an intermediate WI-I/O 9-x Module as a repeater.

The foldout sheet WI-GTWY-9-xxx Installation Guide provides an installation drawing appropriate to most applications. Further information is detailed below.

Each WI-GTWY-9-xxx module should be effectively earthed/grounded via the "GND" terminal on the WI-I/O 9-x module - this is to ensure that the surge protection circuits inside the module are effective.

3.2 Antenna Installation

The WI-GTWY-9-xxx and WI-I/O 9-x modules will operate reliably over large distances. The distance which may be reliably achieved will vary with each application - depending on the type and location of antennas, the degree of radio interference, and obstructions (such as hills or trees) to the radio path. Typical reliable distances are :

USA/Canada 15 miles 6dB net gain antenna configuration permitted (4W ERP) Australia/NZ 12 km unity gain antenna configuration (1W ERP)

Longer distances can be achieved if one antenna is mounted on top of a hill. To achieve the maximum transmission distance, the antennas should be raised above

intermediate obstructions so the radio path is true “line of sight”. Because of the curvature of the earth, the antennas will need to be elevated at least 15 feet (5 metres) above ground for paths greater than 3 miles (5 km). The modules will operate reliably with some obstruction of the radio path, although the reliable distance will be reduced. Obstructions that are close to either antenna will have more of a blocking effect than obstructions in the middle of the radio path. For example, a group of trees around the antenna is a larger obstruction than a group of trees further away from the antenna. The WI-GTWY-9-xxx modules provide a test feature that displays the radio signal strength.

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Line-of-sight paths are only necessary to obtain the maximum range. Obstructions will reduce the range, however may not prevent a reliable path. A larger amount of obstruction can be tolerated for shorter distances. For very short distances, it is possible to mount the antennas inside buildings. An obstructed path requires testing to determine if the path will be reliable refer the section 6 of this manual.

Longer distances can be achieved using the licensed 105U units, because they use a lower frequency and licensed conditions generally allow a higher RF power to be used.

Where it is not possible to achieve reliable communications between two modules, then another WI-I/O 9-x or WI-GTWY-9-xxx module may be used to receive the message and re-transmit it. This module is referred to as a repeater.

An antenna should be connected to the module via 50 ohm coaxial cable (eg RG58, RG213 or Cellfoil) terminated with a male SMA coaxial connector. The higher the antenna is mounted, the greater the transmission range will be, however as the length of coaxial cable increases so do cable losses. For use on unlicensed frequency channels, there are several types of antennas suitable for use. It is important antenna are chosen carefully to avoid contravening the maximum power limit on the unlicensed channel - if in doubt refer to an authorized service provider.

The net gain of an antenna/cable configuration is the gain of the antenna (in dBi) less the loss in the coaxial cable (in dB).

The maximum net gain of the antenna/cable configuration permitted is Country Max. gain (dB)

USA / Canada 6 Australia / New Zealand 0 The gains and losses of typical antennas are

Antenna Gain (dB) Weidmuller Part Nos.

Dipole with integral 15’ cable 0 WI-ANT-DPL-0-16 5dBi Collinear (3dBd) 5 WI-ANT-COL-5-32 8dBi Collinear (6dBd) 8 WI-ANT-COL-8-54 6 element Yagi 10 WI-ANT-YGI-10-6 16 element Yagi 15 WI-ANT-YGI-15-16

Cable type Loss (dB per 30 ft / 10 m) RG58 -5 RG213 -2.5 Cellfoil -3 WI-CCSMA-N-33 (33’ or 10m)

Cellfoil -6 WI-CCSMA-N-66 (66’ or 20m)

The net gain of the antenna/cable configuration is determined by adding the antenna gain and the cable loss. For example, a 6 element Yagi with 66 feet (20 meters) of Cellfoil has a net gain of 4dB (10dB – 6dB).

+ 148 hidden pages

Weidmuller WI-GTWY-9, WI-GTWY-9-MD1 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual