Weidmuller WI-I-O-EX User Manual

User Manual

WI-I/O-EX Serial I/O Module

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

Tel: [phone] Fax: [phone] Email: [e-mail]

Web: www.weidmuller.com

WI-I/O-EX Serial I/O Module User Manual v1.11

Thank you for your selection of the WI-I/O-EX Serial I/O 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-I/O-EX product enjoys a long life,

double check ALL your connections with the User Manual

before turning the power on.

All equipment must be properly grounded for safe operation.

All equipment should be serviced only by a qualified technician.

Important Notice

Weidmuller, Inc. products are designed to be used in industrial environments, by
experienced industrial engineering personnel with adequate knowledge of safety design
considerations. These products should not be used in non-industrial applications, or life­support systems, without consulting Weidmuller, Inc. first.

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 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.

Page 2 February 2010

WI-I/O-EX Serial I/O Module User Manual v1.11

CONTENTS

1 OVERVIEW ............................................................................................................... 4

1.1 MODULE TYPES AND FEATURES .........................................................................................5

1.1.1 Digital inputs / outputs................................................................................................6

1.1.2 Pulsed outputs.............................................................................................................6

1.1.3 Pulsed inputs...............................................................................................................7

1.1.4 Analog inputs..............................................................................................................7

1.1.5 Analog outputs............................................................................................................8

1.1.6 Communications.........................................................................................................9

2 INSTALLATION ..................................................................................................... 10

2.1 GENERAL INSTALLATION .................................................................................................10

2.1.1 Power Connection.....................................................................................................10

2.1.2 Address Switches......................................................................................................10

2.2 SIGNAL CONNECTIONS.....................................................................................................12

2.2.1 Digital Inputs (and Pulsed Inputs) ............................................................................12

2.2.2 Digital Outputs (and Pulsed Outputs).......................................................................13

2.2.3 Analog Inputs............................................................................................................13

2.2.4 Analog Outputs.........................................................................................................17

3 CONFIGURATION ................................................................................................. 20

3.1 ADD A RADIO MODULE TO CONNECT THE WI-I/O-EX TO THE RADIO NETWORK.............20

3.2 ADD THE SERIAL MODULE...............................................................................................20

4 HARDWARE CONFIGURATION........................................................................ 23

4.1 CONNECTING TO THE WI-I/O-EX MODULE......................................................................23

4.2 CONFIGURATION COMMON TO ALL MODULES .................................................................24

4.2.1 Communications.......................................................................................................24

4.2.2 Pulsed outputs...........................................................................................................25

4.3 WI-I/O-EX-11 CONFIGURATION ......................................................................................26

4.3.1 Pulsed Inputs.............................................................................................................26

4.4 WI-I/O-EX-12 CONFIGURATION ......................................................................................27

4.4.1 Voltage input ............................................................................................................27

4.4.2 Current input.............................................................................................................30

4.5 WI-I/O-EX-13 CONFIGURATION ......................................................................................33

4.5.1 Voltage output ..........................................................................................................33

4.5.2 Current output...........................................................................................................35

5 OPERATION............................................................................................................ 37

5.1 WI-I/O-EX-11 MODULE ...................................................................................................37

5.2 WI-I/O-EX-12 MODULE ...................................................................................................39

5.3 WI-I/O-EX-13 MODULE ...................................................................................................40

5.4 HEXADECIMAL REPRESENTATION OF VOLTAGE AND CURRENT LEVELS..........................42

APPENDIX A. MODBUS ADDRESS MAP................................................................. 43

A.1. WI-I/O-EX-11.....................................................................................................................43

A.2. WI-I/O-EX-12.....................................................................................................................45

A.3. WI-I/O-EX-13.....................................................................................................................47

APPENDIX B. MODBUS FUNCTIONALITY............................................................ 49

APPENDIX C. COMMS RECOVERY ........................................................................ 50

APPENDIX D. SPECIFICATIONS .............................................................................. 53

WI-IO-EX Manual v1.11 Page 3

WI-I/O-EX Serial I/O Module User Manual v1.11

APPENDIX E. RS232 WIRING .................................................................................... 55

1 Overview

The WI-I/O-EX modules are designed to provide I/O expansion for other products like
WI-I/O 9, WI-MOD-9-E and WI-MOD-E modules. The WI-I/O-EX modules support the
WI Series protocol, and communicate serially via RS232 or RS485. Configuration is
done via the WI Series configuration utility.

The WI-I/O-EX modules also support ModBus protocol. They may be used as a ModBus
slave with any 3rd-party ModBus device, or with the WI-GTWY modules using ModBus.
They support both ModBus ASCII protocol, and serial un-signed ModBus RTU, also
known as “ModBus binary”. The ModBus slave address of the WI-I/O-EX is selected via
two rotary switches on the bottom panel of the case.

All WI-I/O-EX models provide digital inputs and outputs. Specific models provide
analog inputs or analog outputs. Pulsed inputs and pulsed outputs are also available.
Several modules may be connected to one master, allowing any combination of I/O types.

Figure 1-1 shows a diagram of a WI-I/O-EX module with parts labelled.

Page 4 February 2010

WI-I/O-EX Serial I/O Module User Manual v1.11

access panel

Status LEDs

RS485 and
power connector

Address switches

I/O connector

RS485
termination
switch

RS232 configuration
connector

DIN rail mount

Power

OK

Transmit

Receive

Analog
configuration

Figure 1-1: WI-I/O-EX unit with significant parts labeled.

Two ports allow configuration and communications on the WI-I/O-EX. The RS232 port
is intended for configuration. The RS485 port allows the unit to be in a multi-drop
configuration.

Overvoltage protection and supply monitoring is provided to minimize the risk of failure
due to faulty connections or supply surges.

1.1 Module types and features

The module types and I/O are summarized in Table 1-1.

WI-IO-EX Manual v1.11 Page 5

WI-I/O-EX Serial I/O Module User Manual v1.11

WI-I/O-EX -11 -12 -13

Digital inputs/outputs

Pulse outputs

Pulse inputs

Analog inputs

Analog outputs

Up to 16 Up to 8 Up to 8

8 8 8

4 - -

- 4 floating or 8 commoned -

- - 8

Table 1-1: Summary of WI-I/O-EX module types and I/O.

1.1.1 Digital inputs / outputs

Each digital I/O channel on the WI-I/O-EX modules can act as either an input or an
output. The input/output direction does not need to be user configured.

Digital inputs are suitable for voltage-free contacts, or NPN-transistor switch devices.

Digital outputs are open-collector transistor outputs, able to switch loads up to 30VDC,
200mA.

If you have wired an input/output channel as an input, it is recommended that you do not
write values to it as an output. No electrical damage will occur if you attempt to use a
channel wired as an input as an output, or vice-versa, however the I/O system will not
operate correctly.

We recommend that the required digital inputs be assigned consecutively from channel 1.
Then use the remaining channels as digital outputs.

1.1.2 Pulsed outputs

The first eight digital channels on each WI-I/O-EX module can be used as pulse outputs.
The maximum output frequency is 100Hz.

A pulse output on the WI-I/O-EX will output the number of pulses equal to the register
value sent by the master. When the master sends a new register value, the WI-I/O-EX
will output additional pulses until the output count is the same as the new value.

Three register values are associated with creating each pulsed output:

• The Count keeps a tally of how many pulses have been output - this is a 16-bit

register and overflows to 0.

• The Target is set by the master, and is the trigger for pulses to be created. The

digital channel outputs pulses until the Count value reaches the Target value. If
the Target register is set to 0, the pulses stop and the Count register is cleared.

• The Update Time is the interval in which the WI-I/O-EX expects to receive

updates to the Target value. The module will output enough pulses for the Count

Page 6 February 2010

WI-I/O-EX Serial I/O Module User Manual v1.11

to reach the Target within the update time. The output pulse rate is determined by
the update time, and the difference between the count and the target.

If the calculated pulse rate is more than the maximum rate (100Hz), the WI-I/O-EX will
output pulses at the maximum rate. At the end of the update time, the count value will be
less than the target. The WI-I/O-EX will then calculate the new required pulse rate for
the next update period, based on the difference between Count and Target values.

If the calculated pulse rate is greater than around three times the maximum rate, pulses
are not output. The Count value will be set to the value of the Target without any pulses
output. Pulses will be output again when the calculated pulse rate falls within the
maximum possible rate.

1.1.3 Pulsed inputs

The first four digital channels on the WI-I/O-EX-1-S-11 module can be used as pulsed
inputs. The maximum input pulse frequency is 1 KHz.

The pulse input channel calculates two register variables, each of which can be read by
the master.

• The Pulse Count is a count of the pulses detected on the channel since the WI-I/O-

EX powered up. The pulse input counts are 32-bit values (2 x 16-bit registers, a low
and a high register), and wrap around to zero on overflow.

• The Pulse Rate is a measure of the rate of pulses detected on the channel. The pulse

rate value is decimal 16,384 (hex 4000) for zero rate and decimal 49,152 (hex C000)
for the maximum rate configured by the user. These zero and maximum values are
the same as 0% and 100% used for analog values. (See section 5.4 for hex to decimal
conversion.)

The maximum pulse input rate is set during configuration. The value is in pulses per
minute and is limited to 60000 (1 KHz), the maximum rate capable of the module.

1.1.4 Analog inputs

The analog inputs on the WI-I/O-EX-1-S-12 can be connected as either grounded single­ended inputs or as floating differential inputs. The WI-I/O-EX-1-S-12 has eight
grounded inputs or four floating inputs.

• Grounded single-ended inputs connect between the AIN terminal and the GND

terminal.

• Floating differential inputs each take up two terminals. There are four differential

pairs on the WI-I/O-EX-1-S-12: [AIN1-AIN2], [AIN3-AIN4], [AIN5-AIN6], [AIN7­AIN8]. For example, the first input is connected to terminals AIN1 (positive) and
AIN2 (negative).

WI-IO-EX Manual v1.11 Page 7

WI-I/O-EX Serial I/O Module User Manual v1.11

The two types of input cannot be mixed - all inputs must be either “grounded” or
“floating”.

Inputs can also be selected as mA current, or voltage input - all inputs must be the same,
either all current or all voltage. The scale of each analog input is chosen during hardware
configuration, with scale options as follows:

Voltage input scale options: [0 to 5V], [0 to 10V], [1 to 5V]
Current input scale options: [0 to 10mA], [0 to 20mA], [4 to 20mA]

For compatibility with E-Series modules, 4-20mA current is recommended. See section

4.4 for more information on compatibility.

The values on the analog input are decimal 16,384 (hex 4000) for minimum signal (0%)
and decimal 49,152 (hex C000) for maximum (100%).

The analog channel will measure over-scale, up to 150% which will have value 65,536
(hex FFFF). For 4-20mA signals, the channel will measure under-scale down to 0mA
which has a value of 8,192 (hex 2000). (See section 5.4 for hex to decimal conversion.)

The WI-I/O-EX-12 provides a 24V analog loop supply (“ALS”) for powering analog
loops.

1.1.5 Analog outputs

The WI-I/O-EX-1-S-13 has eight analog output channels and can be configured to output
voltage or current. For current signals, “source” or “sink” can be selected. The scale of
each analog output is specified during configuration, with scale options as follows:

Voltage output scale options: [0 to 5V], [0 to 10V], [1 to 5V]
Current output scale options: [0 to 10mA], [0 to 20mA], [4 to 20mA], source or sink

• Voltage outputs are measured with respect to the ground terminal.

• Current source outputs are measured with respect to the ground terminal.

• Current sink outputs are measured with respect to the 24V “ALS” terminal.

Writing to the output register by the master produces the analog output. Minimum to
maximum signals (0 – 100%) are produced by register values from decimal 16,384 to
49,152 (hex 4000 - C000). (See section 5.4 for hex to decimal conversion.)

The analog channel can output over-scale, up to 150% corresponding to register value
65,536 (hex FFFF). For 4-20mA signals, the channel can output under-scale down to
0mA from a register value of 8,192 (hex 2000) or less. Note that the over-scale output is
limited by the maximum levels capable of the WI-I/O-EX module (12V or 24mA).

Page 8 February 2010

WI-I/O-EX Serial I/O Module User Manual v1.11

1.1.6 Communications

The WI-I/O-EX modules have two communication ports: RS232 and RS485. The RS485
port communicates using E-Series protocol. Both ports support ModBus protocol.

The RS232 port is intended for configuration. The RS485 port is intended for normal
operation and can be used in a multi-drop setup.

There are two address switches on the base of the module. Setting both address switches
to 00 configures the module to use E-Series protocol on the RS485 port. When the
switches are set within the range 01-99, the module uses ModBus protocol on the RS485
port, with the ModBus address defined by the switches. Whenever these address switches
are changed the unit should be reset by disconnecting power.

When using E-Series protocol, the port settings are fixed at 9600 baud, 8 data bits, no
parity, 1 stop bit.

The ModBus communications settings are configurable as follows:
ModBus type: RTU, ASCII with 8 data bits, ASCII with 7 data bits. (Note that the
configuration software only supports ModBus RTU. A ModBus Master can select ASCII
protocol by writing to the appropriate register. See Appendix A.)
Baud rate: 1200, 2400, 4800, 9600, 14400, 19200, 28800, 38400, 57600, 76800, 115200
Parity: none, odd, even
Stop bits: 1 or 2.

The modules are fitted with a termination switch for the RS485. Set this switch only on
the last module in a multi-drop RS485 configuration.

The WI Series software is used to configure the WI-I/O-EX modules as part of a network.
The hardware set-up for items such as expected pulse rates and analog signals is also
available through this software.

When used as a ModBus-only device, stand-alone configuration software (cfg_WI-I/O­EX_Vx.xx.exe) is available to set up the modules. All required software may be
downloaded from the Weidmuller website (http://wireless.weidmuller.com).

WI-IO-EX Manual v1.11 Page 9

WI-I/O-EX Serial I/O Module User Manual v1.11

B A

-

+

2 Installation

All connections to the module should be SELV only. Normal 110/220/240V mains
supply should not be connected to any input terminal of the module.

2.1 General installation

Several WI-I/O-EX modules may be connected to one master via RS485 multi-drop
connection as shown in Figure 2-1. Ensure there is good grounding between the WI-I/O­EX units and the master. A 2.5 mm2 / 12 gauge earth wire is recommended.

Master

WI-I/O-EX

WI-I/O-EX WI-I/O-EX

Figure 2-1: Several WI-I/O-EX units connected to a master.

2.1.1 Power Connection

The WI-I/O-EX modules require a 10.8-30 VDC ** power supply. This is supplied to the
4-way connector, shown in Figure 2-2.

Figure 2-2: Power and RS485 connector. Connect 10.8-30 VDC** to + and earth to -.
Connect RS485 to B and A.

** Model Dependent. Check rear label for actual operating voltages

2.1.2 Address Switches

The address switches are found on the bottom panel of the module, as shown in Figure
2-3. If you are using the WI-I/O-EX module with other modules WI-I/O 9, WI-MOD-9-E
and WI-MOD-E modules), the address switches must be set to “00”. This enables E­Series protocol mode.

If you are using a ModBus Master device, ensure each WI-I/O-EX connected to the same
ModBus master has a unique ModBus address.

Note that the module must be reset after changing the address switches.

Page 10 February 2010

WI-I/O-EX Serial I/O Module User Manual v1.11

A B

A B A B A B

Ω

You can connect to an WI-GTWY-9-MD1 Module using either MODBUS protocol or E­Series protocol. E-Series protocol is easier to set up, and we recommend using this
protocol for most applications.

x10 x1

Figure 2-3: Address switches. The address shown is 01.

Connect the RS485 B and A wires to the 4-way connector shown previously in Figure
2-2. An RS485 termination switch is provided. Terminate the last WI-I/O-EX module in
the multi-drop setup as shown in Figure 2-4.

Up = terminate

Down = unterminated

ON

RS485

termination

switch.

120

Master

WI-I/O-

EX

WI-I/O-

EX

WI-I/O-

EX

Termination
switch up
(terminated)

Figure 2-4: RS485 multi-drop connection and termination (only use external
termination for the master if it does not have internal termination).

WI-IO-EX Manual v1.11 Page 11

WI-I/O-EX Serial I/O Module User Manual v1.11

DIO1

DIO2

EARTH

2.2 Signal Connections

All connections to the module should be SELV only. Normal 110/220/240V mains
supply should not be connected to any input terminal of the module.

2.2.1 Digital Inputs (and Pulsed Inputs)

The WI-I/O-EX-1-S-11 supports 16 digital signals, and the WI-I/O-EX-1-S-12 and WI­I/O-EX-1-S-13 support 8 digital signals. Additionally, digital inputs DIO1-4 on the WI­I/O-EX-1-S-11 operate as pulse inputs.

Digital output signals share the same terminals as the Digital input signals, marked DIO1­8, and DIO1-16 on the WI-I/O-EX-1-S-11 module.

A digital input is activated by connecting to EARTH, either by voltage-free contact or by
a transistor switch. Refer to Figure 2-5:

WI-I/O-EX Module

V+

V+

Voltage-free contact

Transistor
switch device

V-

Figure 2-5: Connection of digital inputs.

Page 12 February 2010

WI-I/O-EX Serial I/O Module User Manual v1.11

_

DIO1

DIO2

EARTH

2.2.2 Digital Outputs (and Pulsed Outputs)

The WI-I/O-EX-1-S-11 supports up to 16 digital outputs, shared with the digital input
function on the same terminals. The WI-I/O-EX-1-S-12 and WI-I/O-EX-1-S-13 both
provide 8 digital output signals. These signals are marked DIO1-8, and DIO1-16 for the
WI-I/O-EX-1-S-11. On all WI-I/O-EX modules, DIO1-8 can also operate as pulsed
outputs.

When active, digital outputs provide a transistor switch to EARTH. To connect a digital
output, refer to the diagram in Figure 2-6. A bypass diode is recommended to protect
against switching surges for inductive loads such as relay coils.

WI-I/O-EX Module

DC

Load

+

Max 30VDC

0.2A

V-

Figure 2-6: Connection of digital outputs.

Note that digital outputs will only switch DC circuits, with maximum voltage 30VDC.

2.2.3 Analog Inputs

The WI-I/O-EX-1-S-12 provides eight grounded single-ended or four floating differential
analog inputs. These provide measurement of voltage signals (0-10V) or current (0-20
mA) signals. An internal 24V analog loop supply (ALS) is generated for current loops.

Refer to Section 4.4 for detail on configuring single-ended, differential, current-mode or
voltage mode inputs.

WI-IO-EX Manual v1.11 Page 13

WI-I/O-EX Serial I/O Module User Manual v1.11

AIN1

AIN2

AGND

ALS +24V

+

-

+

-

2.2.3.1 Grounded Single-Ended mA Inputs

Single-ended current inputs allow twice as many inputs as the differential mode. This
mode is useful when the sensor loop can be grounded to the WI-I/O-EX module. Devices
may also be powered by the 24V supplied by the WI-I/O-EX. Refer to Figure 2-7:

Loop powered

sensor

WI-I/O-EX Module

Externally powered

sensor

V-

Figure 2-7: Connection for single-ended current inputs. Transducers may be
externally powered or powered by the WI-I/O-EX +24V loop supply (ALS).

Note:

- The module is configured at the factory for this type of input

- To change the input configuration, refer to section 4.4

Page 14 February 2010

WI-I/O-EX Serial I/O Module User Manual v1.11

AIN3

AIN4

AGND

ALS +24V

Externally powered

+

-

AIN1

AIN2

+

-

2.2.3.2 Floating Differential Mode mA Inputs

Differential mode current inputs should be used when measuring a current loop which
cannot be connected to earth or ground. This allows the input to be connected anywhere
in the current loop. Common mode voltage can be up to 27VDC.

Up to four loops can be connected, to terminal pairs [AIN1-AIN2], [AIN3-AIN4],
[AIN5-AIN6], [AIN7-AIN8] - the former terminal is positive and the latter negative.
The diagram in Figure 2-8 indicates how to connect devices for differential mode current
inputs.

WI-I/O-EX-1-S-12 Module

Loop powered

sensor

Power
supply

sensor

V-

Figure 2-8: Connections for differential current inputs.

Note:

- The module configuration needs to be changed for this type of input

- To change the input configuration, refer to section 4.4

WI-IO-EX Manual v1.11 Page 15

WI-I/O-EX Serial I/O Module User Manual v1.11

AIN3

AIN4

AGND

AIN1

AIN2

+

-

+

-

2.2.3.3 Floating Differential Voltage Inputs

Differential voltage inputs allow a voltage to be measured when it cannot be referenced
to earth or ground. The diagram in Figure 2-9 shows how to connect differential voltage
inputs. The module has a 27V common mode input range.

WI-I/O-EX-1-S-12 Module

ALS +24V

Sensors with

voltage signals

V-

Figure 2-9: Connection for differential voltage input mode.

Note:

- The module configuration needs to be changed for this type of input

- To change the input configuration, refer to section 4.4

Page 16 February 2010

WI-I/O-EX Serial I/O Module User Manual v1.11

AIN1

AIN2

AGND

ALS +24V

2.2.3.4 Single-ended Voltage Input

Single-ended voltage inputs allow twice as many inputs as differential mode. This mode
is useful when one end of the input voltage can be connected to the ground of the WI-I/O­EX module. Figure 2-10 shows connections for single-ended voltage input.

WI-I/O-EX-1-S-12 Module

Sensor with voltage

signal

V-

Figure 2-10: Connection for single-ended voltage input.

Note:

- The module configuration needs to be changed for this type of input

- To change the input configuration, refer to section 4.4

2.2.4 Analog Outputs

The WI-I/O-EX-1-S-13 provides eight analog outputs. These may be configured as
voltage or current outputs. The current output may be selected as “sink” or “source”
current.

Refer to Section 4.5 for detail on configuring analog outputs.

WI-IO-EX Manual v1.11 Page 17