USER MANUAL

FOR

FIOA-0402-U
COPYRIGHT NOTICE
This manual is a publication of Renu Electronics Pvt. Ltd. and is provided for use by its customers only.
The contents of the manual are copyrighted by Renu Electronics; reproduction in whole or in part, for use
other than in support of Renu Electronics equipment, is prohibited without the specific written permission
of Renu Electronics.

SERVICE
If service is required then pack the unit in its original packaging container or, if unavailable, any suitable
rigid container. If a substitute container is used, surround the unit with shock absorbing material; damage
in shipment is not covered by the warranty. Include a letter with the unit describing the difficulty and
Hardware Revision and Software Version. Send to the following address:

Renu Electronics Pvt. Ltd.

Survey No. 2/6,
Baner Road,
Pune-411045

All returns will be tested to verify customer claims of noncompliance with the product warranty. Improper
return packaging, which makes verification impossible, will void the warranty. If noncompliance is verified
and is not due to customer abuse or the other exceptions described with product warranty, Renu
Electronics will, at its option, repair or replace the Product returned to it, freight prepaid, which fail to
comply with the foregoing warranty, provided REPL is notified of such noncompliance within the one-year
warranty period.

ASSISTANCE
This manual is designed to provide the necessary information for trouble-free installation and operation of
your new FIOA Series. However, if you need assistance, please call Renu Electronics Pvt. Ltd. at 91-20-
27292840 or visit our web site at www.renuelectronics.com

MANUAL REVISION
If you contact us in reference to this manual, please include the following document number
Name : User Manual For FIOA-0402-U
Part Number : URML407
Document : UMAN\FIOA-0402-U\0207
Revision : 0.00

Revision Number Document Number Date Description

Rev 0.00 UMAN\FIOA-0402-U\0207 27-02-2007 First Release

 Contents
CH-1 INTRODUCTION 1
1.1 Purpose of this Manual 1
1.2 Introduction to FIOA-0402-U 1
1.3 Specifications: 2
1.4 Power Requirement: 2
CH-2 HARDWARE 3
2.1 Dimensional details and mounting instructions 3
2.2 Communication Port 4
2.3 Communication parameters and Modbus tag definitions: 5
2.4 Configuration: 5
CH-3 GETTING STARTED 6
3.1 Starting Prizm32 software: 6
3.1.1 Installing Prizm32 Software 6
3.1.2 Steps for starting Prizm32 Software 8
3.1.3 Uninstalling Prizm32 Software 8
3.2 Configuration of the unit: 9
3.3 Configuration Downloading procedure: 13
3.3.1 Prizm32 software configuration for downloading: 13
3.3.2 FIOA hardware configuration for downloading: 15
3.4 Upload: 16
CH-4 WIRING DIAGRAM 17
4.1 Analog Inputs: 17
4.2 Analog Outputs: 18
4.3 Multidropping Connection: 18
4.4 Data Output format for analog inputs: 19
4.5 Data entry format for analog outputs: 20
CH-5 CABLE DIAGRAM 21
5.1 IBM cable for downloading configuration: 21
5.2 Modbus master (PRIZM unit) to FIOA unit (2 Wire RS485): 22
5.3 Modbus master (PRIZM unit) to FIOA unit (RS232): 23
5.4 Modbus master (PRIZM unit) to FIOA unit (2 Wire RS485): 24
FIOA-0402-U Manual

CH-1 INTRODUCTION
1.1 Purpose of this Manual
The intention of this Operation Manual is to provide a guide for Safe installation, Configuration and opera-
tion of FIOA unit.
Read this operation manual thoroughly before installing and operating the FIOA unit.
This document is based on information available at the time of its publication. While efforts have been
made to be accurate, the information in this document may not cover all the details or variations in hard-
ware or software. Renu Electronics reserves the right to update information in this publication without prior
notice.

1.2 Introduction to FIOA-0402-U

FIOA 0402 U is Analog Input Output Model having 4 Universal Analog inputs and 2 Analog outputs. The
Analog inputs can be Voltage ( 0-10V), Current (0 –20 mA, 4 – 20 mA), mV ( 0 –100 mV, 0 – 50 mV ), RTD
( PT 100 Alpha1 and Alpha2 constant ), Thermocouple ( B,R,S,E,J,K,N,T ). Each input channel can be
configured independently to work as any of the above type as per configuration made in the PRIZM
software. The Analog outputs can be Voltage ( 0 – 10 V) or Current ( 4 – 20 mA). Output channels also are
software configurable to current or voltage.
Unit supports standard Modbus RTU (slave) protocol for communicating with master device.
Internal circuitary (analog, digital and communication) is completely isolated from external power supply of
the unit. Also communication section is isolated from the internal circuit.

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FIOA-0402-U Manual

1.3 Specifications:
1. Power Supply : 24 VDC +/- 10%
2. Number of analog Inputs : 4
3. Number of analog outputs : 2
4. Analog Inputs : Voltage (0-10V),
Current (0 –20 mA, 4 – 20 mA),
mV (0 –100 mV, 0 – 50 mV),
RTD (PT 100 Alpha1 and Alpha2 constant),
Thermocouple (Type: B, R, S, E, J, K, N, T)
5. Analog Outputs : Voltage ( 0 – 10 V) and Current ( 4 – 20 mA)
6. Resolution : 12 Bit
7. Communication Port : 1. RJ45: RS232, 2-wire RS485, CMOS
2. Same 2 wire RS485 signals are available on
pluggable terminals
8. I/O Terminals : Pluggable terminals.
9. Operating Temperature : 0OC to 60OC
10. Storage Temperature : -20OC to 80OC
11. Humidity : 10% to 90% (Non condensing)
12. Mounting : DIN rail mounting
13. Dimensions (DIN rail) : 70 X 100 X 35 mm

1.4 Power Requirement:

FIOA is a 24VDC powered unit. Power should be applied on the PCB Terminal block on the unit. Power
rating is +24VDC +/- 10%.

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FIOA-0402-U Manual

CH-2 HARDWARE
2.1 Dimensional details and mounting instructions
Following sketch shows dimensional details of FIOA with the mounting clamp.

70.
00

100.00

.00
35

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FIOA-0402-U Manual

2.2 Communication Port

The RJ 45 COM Port has RS 232, RS 485 (two wire) and CMOS logic signals on its pins. This port can be
used to download the configuration in the unit from the PRIZM software as well as for communication with
any Modbus Master device. Same two wire RS 485 signals are provided on the terminal block for commu-
nication with Modbus Master Device.

Pinouts of RJ connector is as shown below:

4. DATA+ (A) 5. DATA- (B)

3. GND 6. Terminal resistor
2. RS232 RX 7. NC
1. RS232 TX 8. CMOS_TX
PIN1 PIN8

COMM Port
2 Wire RS485 connections on terminal block:

POWER
COMM
CS11
ERR
IN1+
AGND
FIOA
I1-
CS21 0402-U
M
IN2+
GND
GND GND
AGND GND A
I2- S
B B B
CS31
T
COMM PORT

IN3+
E
AGND A A A
I3- 120W R
CS41 TERM TERM
TERM
REST REST
REST
IN4+
AGND
NC NC
GND
I4-
B
VO1 DC+ DC+
IO1
A
+ 24VDC
TERM
REST
DC- - +/- 10%
AGND
NC DC-
DC-
VO2 DC+

IO2 DC-
AGND EARTH

For using internal termination resistor (120 Ohm),

short “B” and “TERM REST”

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FIOA-0402-U Manual

2.3 Communication parameters and Modbus tag definitions:

Unit supports standard Modbus RTU (slave) protocol for communicating with master device.

Driver: Modbus RTU (slave)

Baud Rate: 9.6K, 19.2K, 57.6K OR 115.2K (Software Configurable)
Stop Bit: 1
No. of data bits: 8
Parity: Odd, Even OR None (Software Configurable)
Station ID: 1 to 255 (Software Configurable)

The following dedicated modbus registers are assigned to analog inputs:

SR. No. Analog Inputs MODBUS Tag.

1. INPUT 1 40001
2. INPUT 2 40002
3. INPUT 3 40003
4. INPUT 4 40004

The following dedicated modbus registers are assigned to analog oututs:

SR. No. Analog Outputs MODBUS Tag.

1. OUTPUT 1 40065
2. OUTPUT 2 40066

2.4 Configuration:

FIOA 0402-U requires PRIZM 32 software to configure analog input and outputs.
For downloading configuration use RJ COM Port of the unit.

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FIOA-0402-U Manual

CH-3 GETTING STARTED

3.1 Starting Prizm32 software:
3.1.1 Installing Prizm32 Software
System requirements for installing Prizm32 on your PC:

Windows Version : Microsoft® Windows 2000 or higher

Processor : 266 MHz Pentium® II or higher Pentium-compatible CPU
Hard disk Space : 150 MB free memory space
Serial Mouse : Microsoft® mouse or compatible pointing device
RAM : At least 64 megabytes (MB) of RAM; more memory
generally improves responsiveness
Display resolution : 800 X 600 with 24 bit true color
Serial Port : One Serial Port for Downloading Required

To install Prizm32 Software:

1. Open Microsoft® Windows.
2. Select Run and Pop up window appears. Type the path for installing the Setup.
This will install Prizm32 Setup Software.
3. When you click on OK, Welcome window appears on the screen. Click on Next.

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FIOA-0402-U Manual

4. Enter user name and company name.

5. Select the destination folder where Setup will install the files.

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7. Installation starts. A dialog box indicating the status of progress of installation will display.
A screen is displayed to inform you when installation is completed.
This procedure installs Prizm32 Software in Start Menu (in selected folder).

3.1.2 Steps for starting Prizm32 Software

1. In Windows click the Start button.
2. Select Programs.
3. Select Prizm32.
4. Select New Application either from Tool station or from File Menu.
5. Select the product by clicking on picture of the product in the list.
6. Select model from model list.
7. Set configuration parameters for analog inputs, outputs and communication port settings.

3.1.3 Uninstalling Prizm32 Software

1. In Windows click the Start button.

2. Select Programs.
3. Select Prizm32.
4. Select Uninstall Prizm32.
Following screen will display. The screen will ask you for the confirmation for uninstalling Prizm32.

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FIOA-0402-U Manual

7. When you click Yes button, it will uninstall Prizm configuration from your computer.
If you want to install Prizm32 again you have to follow the steps explained in section 3.3.1.

3.2 Configuration of the unit:

1. When you launch Prizm32 setup software and select FIOA unit as shown below:

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2. Select model from model list. Press “Next”. This will give you a analog I/O configuration wizard as
shown below:

Analog Input Configuration

Enable Analog Input: Check this check box to enable the selection of Analog Input channel.
Channel no: Channel number depends on the selection of FIOA model. Here user can configure 4 input
channels as selected FIOA model has 4 inputs.
Channel Type: Here selected model supports Universal inputs, so channel types are Thermocouple, mV,
mA, RTD and Voltage.

Each input channel can be configured independently as any of the input channel type.

Analog Output Configuration

Enable Analog Output: Check this check box to enable the selection of Analog Output channel.

Channel no: Channel number depends on the selection of FIOA model. Here user can configure 2 output
channels as selected FIOA model has 2 outputs.

Channel Type: Channel types are mA and Voltage.

Each output channel can be configured independently as any of the output channel type.

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3. The Analog Input and Output channel configuration is shown in the following screen:

4. If Thermocouple is selected as Channel type, then Thermocouple types are as shown below.

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5. To configure particular channel select Channel number, Channel type, channel subtype, normalization
factor (0 to 99) and click on Confirm button. The selected channel will be configured.
6. Normalization factor can be selected for each channel independently.
7. Follow the same procedure for configuring Analog Output channel.
8. Also define communication parameter settings. This is done by clicking the “Port Setting” button on the
wizard as shown below:

9. For communicating with master device; Baud rate and parity can select as shown below:

This completes the configuration of FIOA unit in Prizm32 software.

These configuration settings can be saved as “*.pzm” file so that we can use the same configuration next
time.

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FIOA-0402-U Manual

3.3 Configuration Downloading procedure:

3.3.1 Prizm32 software configuration for downloading:
To download the configuration into the unit; follow the below given steps:
1. Press “Download” icon on the screen as shown below:

2. When user press “Download” icon from toolstation window; following screen will apprear:

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FIOA-0402-U Manual

3. Once compiling of project is done then following window is displayed:

Communication Port – This is used to define communication port for downloading. By default Com1 is
selected.

Click “Download” button to start download. By default; this task will complete application and firmware
downloading.
During download operation following error may be occur -
1. Unit is not responding.
This error indicates that no communication has been etablished with unit. Please check cable connection
before you start downloading again.
2. Selected model is not matching with unit connected on IBM port.
This is product mismatch error. Please check you have defined correct model in application configuration.

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FIOA-0402-U Manual

3.3.2 FIOA hardware configuration for downloading:

Follow the below given steps for downloading the application and firmware in the FIOA unit.
1. Remove communication cables from any master device.
2. Connect the IBM programming cable from PC to unit’s RJ45 COM Port.
(You may use RS 232 signals for communicating with PC.)
3. Power ON the FIOA unit.
4. Wait for 10 Seconds. The ERR led will glow. This means the unit is in Configuration Download mode.
5. Configure the input / output channel in the I/O configuration wizard of PRIZM software.
6. Press “Download” button in the Prizm32 software.
7. Prizm software will download the application and firmware in the unit.
8. After the firmware is downloaded connect the unit to Modbus master device.

#Note:
1. For downloading the configuration you must remove communication cables from any master device.
2. Once the unit is turned ‘ON’, ERR Led goes ‘ON’ only after 10 seconds.
3. Press Download only when ERR Led is ‘ON’.
4. If Download is pressed before turning ‘ON’ the ERR Led, you will have to restart the unit.
5. At power ‘ON’ if there is no PLC communication from the Master till 10 seconds, the unit will still enter
into the Configuration download mode, which is indicated by glowing ERR Led. But if any frame from
master arrives, unit will enter in to PLC communication mode switching ‘off’ the ERR Led.
6. ‘ERR’ LED turns OFF after 5 minutes of the power ON; even if there is no any download and no frame
from Modbus master

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FIOA-0402-U Manual

3.4 Upload:
An application can be uploaded from the FIOA unit. To upload an application first select the appropriate
communication port for your computer by choosing “Communicate | Communication Port” menu option.
Attach a computer to FIOA cable. From the “Communicate” menu, click on the “Upload...” selection.

OR

In the Upload dialog, check the “Application” button and press the “Upload” button to begin uploading
the application.

Thus the application upload can be performed.

For uploading, hardware configuration is same as that for the downloading configuration of the unit.

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CH-4 WIRING DIAGRAM

4.1 Analog Inputs:
1. Current Input Connections:

mA + -

CS IN+ AGND I-

CURRENT

2. Voltage Input Connections:

V / mV + -

CS IN+ AGND I-

VOLTAGE & mV

3. RTD Input Connections:

RTD

CS IN+ AGND I-

3 WIRE RTD
4. Thermocouple Input Connections:

TC + -

CS IN+ AGND I-

THERMOCOUPLE

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FIOA-0402-U Manual

4.2 Analog Outputs:

1. Current Output Connections:
Iout

VO IO AGND

2. Voltage Output Connections:

Vout

VO IO AGND

4.3 Multidropping Connection:

M
GND
A
S
FIOA Unit 1 B
T
E
A
R

FIOA Unit 2

FIOA Unit “n”

Note: Where “n” is upto 32. Connecting one
repeater can increase it to 64 and so on.
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FIOA-0402-U Manual

4.4 Data Output format for analog inputs:

For Voltage (0 to 10V)

Voltage Input Count

0V 0
2.5V 1024
5V 2048
7.5V 3072
10V 4095

For Milivolt (0 to 100mV) Milivolt (0 to 50mV)

mV Input Count mV Input Count

0mV 0 0mV 0
25mV 1024 12.5mV 1024
50mV 2048 25mV 2048
75mV 3072 37.5mV 3072
100mV 4095 50mV 4095

For Current (0 to 20mA) current (4 to 20mA)

Current Input Count Voltage Input Count

0mA 0 4mA 0
5mA 1024 8mA 1024
10mA 2048 12mA 2048
15mA 3072 16mA 3072
20mA 4095 20mA 4095

For RTD & Thermocouple

Output data will be in multiple of 10 of the actual temperature in degrees. It will be in the SIGNED
INTEGER format.

For Example: If temperature is 23.4 OC, data will be 234. AND

If temperature is -57.1 OC, data will be -571.
#Note: Selecting unsigned integer format at Modbus master will give wrong readings for the negative
temperature range.

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FIOA-0402-U Manual

4.5 Data entry format for analog outputs:

For Analog output, enter the digital count for respective output register and observe the current & voltage
output on multimeter. It should be as per following table.
1. For Current (4 to 20 mA) 2. For Voltage (0 to 10 V)

Entered count Current output Entered count Voltage output

0 4mA 0 0V
1024 8mA 1024 2.5V
2048 12mA 2048 5V
3072 16mA 3072 7.5V
4095 20mA 4095 10V

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CH-5 CABLE DIAGRAM

5.1 IBM cable for downloading configuration:
PC SIDE FIOA UNIT SIDE

IBM 2 mtr.

DB9 FEMALE RJ45 CONNECTOR

(RS232) Shield Wire (RS232)

SIGNALS Pin # Pin # SIGNALS

1 1 TXD

RXD 2 2 RXD

TXD 3 3 SG

4 4

SG 5 5

6 6

7 7

8 8

9 Shield Wire
DB9 FEMALE PINOUTS RJ45 CONNECTOR PINOUTS
FRONT VIEW R.H.S. VIEW

Pin 1 Pin 8
(Left side) (Right side)
5
9

6
1

Cable insert end

Cable insert end

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FIOA-0402-U Manual

5.2 Modbus master (PRIZM unit) to FIOA unit (2 Wire RS485):

PRIZM SIDE FIOA UNIT SIDE

2 mtr.
PLC

DB9 MALE RJ45 CONNECTOR

(RS485) Shield Wire (RS485)

SIGNALS Pin # Pin # SIGNALS

TX+ 1 1

2 A 2

3 3 SG

RX+ 4 4 A

SG 5 5 B

6 6

7 7
B
TX- 8 8

RX- 9 Shield Wire

DB9 MALE PINOUTS RJ45 CONNECTOR PINOUTS
FRONT VIEW R.H.S. VIEW

Pin 1 Pin 8
(Left side) (Right side)
1
6

9
5

Cable insert end

Cable insert end

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FIOA-0402-U Manual

5.3 Modbus master (PRIZM unit) to FIOA unit (RS232):

PRIZM SIDE FIOA UNIT SIDE

2 mtr.
PLC

DB9 MALE RJ45 CONNECTOR

(RS232) Shield Wire (RS232)

SIGNALS Pin # Pin # SIGNALS

1 1 TXD

TXD 2 2 RXD

RXD 3 3 SG

4 4

SG 5 5

6 6

7 7

8 8

9 Shield Wire
DB9 MALE PINOUTS RJ45 CONNECTOR PINOUTS
FRONT VIEW R.H.S. VIEW

Pin 1 Pin 8
(Left side) (Right side)
1
6

9
5

Cable insert end

Cable insert end

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FIOA-0402-U Manual

5.4 Modbus master (PRIZM unit) to FIOA unit (2 Wire RS485):

POWER
COMM
CS11
ERR
IN1+
AGND
FIOA
I1-

FIOA SIDE CS21

IN2+
0402-U
AGND

GND I2-

CS31

COMM PORT
B IN3+

PRIZM SIDE AGND

A I3-
CS41

TERM IN4+
REST AGND
GND
I4-
NC B
PLC

VO1
A
IO1
DC+ AGND
TERM
REST
NC

DC- VO2 DC+

IO2 DC-
AGND

WIRE OUTS
SIGNAL FROM PLC Shield Wire

SIGNALS Pin #
Signals
RX+ YELLOW
A
TX+ GREEN

BLACK SG
SG

RX- WHITE
B
TX- BLUE

DB9 MALE PINOUTS

Shield Wire
1 5

6 9

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