1 - EZAutomation

EZ Remote IO 

Hardware Manual -Revision A.1 

Manual Part Number EZ RIO-M 

EZ Remote IO H/W Manual -Cover 

EZ Remote IO -Cover Page

This page intentionally left blank.

EZ Remote IO 

Hardware Manual -Revision A.1 

Manual Part Number EZ RIO-M

WARNING 

WARNING! 

Control devices such as EZ Remote IO are not fail-safe devices and as such must not be used for stand-alone 

protection in any application. Unless proper safeguards are used, unwanted start-ups could result in equipment 

damage or personal injury. The operator must be made aware of this hazard and appropriate precautions must 

be taken. In addition, consideration must be given to the use of an emergency stop function that is independent 

of the EZ Remote IO. 

The diagrams and examples in this user manual are included for illustrative purposes only. The manufacturer 

cannot assume responsibility or liability for actual use based on the diagrams and examples. 

Trademarks 

This publication may contain references to products produced and/or offered by other companies. The product 

and company names may be trademarked and are the sole property of their respective owners. EZAutomation 

disclaims any proprietary interest in the marks and names of others. 

Manual part number EZ RIO-M 

© Copyright 2007, EZAutomation 

All Rights Reserved 

No part of this manual shall be copied, reproduced, or transmitted in any way without the prior written consent of 

EZAutomation. EZAutomation retains the exclusive rights to all information included in this document. 

Designed and Built by AVG 

4140 Utica Ridge Rd. • Bettendorf, IA 52722-1327 

Marketed by EZAutomation 

4140 Utica Ridge Road • Bettendorf, IA 52722-1327 

Phone: 1-877-774-EASY • Fax: 1-877-775-EASY • www.EZAutomation.net 

EZ RIO-M

v 

Table of Contents 

EZ Remote IO H/W Manual -Cover 

WARNING 

EU Information 

Chapter 1 - Getting Started 

1.1 Introduction 1-2 

1.2 Purpose of the Manual 1-3 

1.3 EZ Remote IO System Overview 1-4 

1.4 EZ Remote IO Specifications 1-5 

1.5 Components of the EZ Remote IO System 1-7 

1.6 Part Numbering of the EZ Remote IO Components 1-8 

1.7 Quick and EZ Start to Get Familiar with EZ Remote IO 1-10 

Chapter 2 - Installation 

2.1 EZ Remote IO Mounting 2-2 

2.2 EZ Remote IO Base Wiring 2-7 

2.3 EZIO Modules Positioning 2-10 

2.4 EZIO Mounting and Wiring 2-12 

2.5 Safety Considerations 2-14 

2.6 Installation Considerations 2-15 

2.7 Electrical Considerations 2-17 

2.8 Sourcing (P type) and Sinking (N type) I/O 2-24 

Chapter 3 - DeviceNet Configuration and Installation 


3.2 Installation and Wiring 3-3 

3.3 DeviceNet Module Configuration 3-7 

Chapter 4 - Profibus Configuration and Installation 


4.2 Installation and Wiring 4-2 

4.3 Profibus Module Configuration 4-6 

Index


vi 


. 

EZ Remote IO is manufactured in compliance with European Union (EU) Directives and carries the CE mark. 

EZ Remote IO has been tested under CE Test Standard #EN55011, and is submitted for UL Certification. 

. 

Please Note 

Products with CE marks perform their required functions safely and 

adhere to relevent standards as specified by EU directives provided they 

are used according to their intended purpose and that the instructions in 

this manual adhere to. The protection provided by the equipment may be 

impaired if this equipment is not used in accordance with this manual. 

Only replacement parts supplied by EZAutomation or its agents should 

be used. 

Technical 

Support 

Consult EZ Remote IO Software Help or you may find answers to your 

questions in the operator interface section of our website @ www. 

EZAutomation.net. If you still need assitance, please call our technical 

support at 1-877-774-EASY or FAX us at 1-877-775-EASY 

SELV Circuits 

All electrical circuits connected to the communications port receptacle are 

rated as Safety Extra Low Voltage (SELV). 

Environmental 

Specifications 

Operating Temperature: -100 to +60 °C 

Storage Temperature: -20 to +70 °C 

Operating Humidity: 10 - 95% R.H., noncondensing 

Air Composition: No corrosive gasses permitted 

Preventative 

Maintenance 

and Cleaning 

No special preventative maintenance is required.

Chapter 1 - Getting Started 1 

Getting Started 

In this chapter.... 

• Introduction 

• Purpose of the Manual 

- Where to get HELP - Technical Support 

• EZ Remote IO System Overview 

• EZ Remote IO Specifications 

• Components of the EZ Remote IO System 

• Part Numbering of the EZ Remote IO System 

• Quick and EZ Start to Getting Familiar with EZ Remote IO 

D R A F T

1-2 Chapter 1 - Getting Started 

1.1 Introduction 

Welcome to EZAutomation’s latest, highly flexible and cost effective EZ Remote IO 

System. EZAutomation is the newest addition to the AVG family, with a 37-year-old 

tradition of manufacturing more than 200 high value and most innovative automation 

products. 

AVG, established in 1975, is an American group of companies comprised of Autotech, 

Uticor, and now EZAutomation. Since its inception, AVG has introduced more than 

500 innovative new products, including PLS, PLCs and Remote IOs. We have more 

than 20 patents in Automation products and 15 new patents are pending. 

Uticor, formerly Struthers Dunn Systems division, has been at the forefront of PLCs, 

welding controls, message displays and operator interface technology since 1968. 

Uticor, in fact, was one of the early inventors of PLCs back in 1968. It held numerous 

patents on PLCs, then called Process Control Computers. 

The EZ Remote IO’s innovation, flexibility, cost-effectiveness and precision, comes 

from Uticor’s 37 years of PLCs experience. 

US Patent No. 

3,761,882 issued to 

Uticor on Sept 25, 1973 

Describing the first time use of 

programmable memories in PLCs


1-3 

1.2 Purpose of the Manual 

This manual is presented with details and step-by-step information on Installation and 

Configuration of a new EZ Remote IO System. It also provides understanding on how to connect 

an EZ Remote IO with other components in your control system. 

This manual is a good reference guide for personnel who install as well as configure EZ Remote 

IO System. If you understand Remote IO in general, you can find all the information you need 

to start and maintain your system in this manual. 

Where to get HELP - Technical Support 

We make every effort to keep our manuals in line with the feedback from our customers. If you 

find it difficult to locate what you are looking for, check the resources listed below for the topic 

you are looking for. 

• Table of Contents: A listing of contents per chapter, at the beginning of manual. 

• Index: 

Index is an alphabetical listing of all key words located at the back 

of the manual. 

• Key Topics for At the begining of each chapter 

Each Chapter: 

Although most of your questions will be answered within this manual, if you still need assistance, 

technical support is available at 1-877-774-EASY. Our voted best Tech Support Engineers are 

available Monday through Friday 6 A.M. to 12 midnight CST. 

You can also reach us at 1-563-650-8112 on the weekends for emergency tech support. We 

may not be able to provide you the level of support available during the week, but we would 

most likely be able to solve your emergency needs. 

You can also visit our website for online resources and the latest product related information. 

Our web address is www.EZAutomation.net. 

Technical Support: 

1-877-774-EASY 

(Mon thru Fri) 

(6am-12pm CST) 

Weekend Emergency 

Technical Support: 

1-563-650-8112


1.3 EZ Remote IO System Overview 

EZ Remote IO is an excellent way to add on a number of I/Os to any Programmable Logic Controller 

at an incredibly low price. Provided that the controller should be capable of communicating on any 

of the following networks -Modbus RTU, Modbus TCP/IP, DeviceNet or Profibus. 

PLC 

Communication Link 

• Modbus RTU 

• Modbus TCP/IP 

• DeviceNet 

• Profibus 

EZ Remote IO 

1 

EZ Remote IO can be added to 

any controller, that is capable of 

communicating on any of the 

above networks 

EZ Remote IO 

2 

EZ Remote IO 

n 

EZ Remote IO bases : 

-Available in four models 4, 6, 8 or 12 slots 

-Respectively 32, 48, 64 or 96 I/O points 

-Either 24 VDC or 110 VAC power input 

-EZ Remote IO has a built-in RS232 port, RS-422 port 

-Optional communication cards for DeviceNet Slave and Profibus Slave 

-Enhanced model comes with additional Ethernet connectivity


1-5 

1.4 EZ Remote IO Specifications 

Part Number 

EZ RIO-A-32 - Standard 

EZ RIO-A-32E - Ethernet 

EZ RIO-D-32 - Standard 

EZ RIO-D-32E - Ethernet 

EZ Remote IO Base Specifications 













Specifications 

Input Voltage Range 

Maximum I/O 

Capacity 

Power Supply 

Capacity 

CPU & Support 

Electronics Power 

I/O Module Power 

(typical) 

DeviceNet/Profibus 

Interface Power 

Maximum Power 

Consumption 

CPU Processor 

LED Indicators 

I/O Supported 

Operating 

Temperature 

Storage 

Temperature 

Humidity 

Electrical Noise 

Agency Approval 

Withstand Voltage 

Insulation 

Resistance 

Vibration 

Shock 

Protocols 

Supported 

4 Slot EZ RIO 

AC Powered 

110 VAC 

(95-125VAC) 

4 Slot EZ RIO 

DC Powered 

24VDC 

(20-28VDC) 

EZ Remote IO models with “E” suffix are built with 10/100 Base-T Ethernet with a standard RJ45 connector 

6 Slot EZ RIO 

AC Powered 

110 VAC 

(95-125VAC) 

6 Slot EZ RIO 

DC Powered 

24VDC 

(20-28VDC) 

8 Slot EZ RIO 

AC Powered 

110 VAC 

(95-125VAC) 

8 Slot EZ RIO 

DC Powered 

24VDC 

(20-28VDC) 

12 Slot EZ RIO 

AC Powered 

110 VAC 

(95-125VAC) 

12 Slot EZ RIO 

DC Powered 

24VDC 

(20-28VDC) 

4 Slot Base (32I/O Max) 6 Slot Base (48I/O Max) 8 Slot Base (64I/O Max) 12 Slot Base (96I/O Max) 

3.3V @ 1 Amp 

300mA 

25mA 

DeviceNet 50mA 

Profibus 100mA 

10 watts 11 watts 12 watts 15 watts 

32 Bit, 40 MHz RISC Processor 

Input Power and CPU Status (Run) active indicators 

EZI/O Snap-in modules with status LEDs and Removable Terminal Block 

DC / AC / Analog / Relay / Thermocouple / High Speed Counter / DeviceNet / Profibus 

-10C to 60C 

-20C to 70C 

10-95% Non-Condensing 

Nema ICS 2-230 Showering arc; ANSI C37.90a SWC; Level C Chattering Relay Test (pending) 

UL, CUL, CE (pending) 

1000VDC (1 minute) between power supply input terminal and protective ground) 

Over 20M Ohm between power supply input and terminal and protective ground 

5 to 55Hz 2G’s for 2 hours in X,Y,and Z axis 

10G for under 12ms in the X,Y, and Z axis 

Modbus RTU, Modbus TCP/IP, DeviceNet , Profibus 

Communication 

Ports 

Standard Model: Port 1: RS232 

Port 2: RS422 

Ethernet Model: Port 1: RS232 

Port 2: RS422 

Port 3: Ethernet 

External 

Dimensions 

5.75” x 4.868” x 3.124” 

(146.05 x 123.65 x 79.356mm) 

8.35” x 4.868” x 3.124” 

(212.09 x 123.65 x 79.356mm) 

9.21” x 5.818” x 3.124” 

(233.93 x 147.78 x 79.356mm) 

14.908” x 5.173” x 3.124” 

(378.65 x 131.4 x 79.356mm)


EZ I/O Module Specifications- 

For the EZ I/O Module Specifications pls refer the EZI/O Manual or you may view the specifications in the 

EZRemote IO Software itself. 

To view the Specification Sheet for an EZI/O Module in the Software, you have got two options: 

1. Right-Click on the EZI/O Module Selection List. 

2. Place the EZI/O module on the EZRemote IO base and then Right-Click on it. 

1. Right-Click on the EZI/O Module Selection List 

2. Place the EZI/O module on the EZRemote IO base and then Right-Click on it


1-7 

1.5 Components of the EZ Remote IO System 

Configuration S/W 

1 

EZ RIO 

Cable 

2 

EZ Remote IO Base 

3 

EZ IO Modules 

5 

DeviceNet 

Profibus 

Communication Options 

Communication 

4 

DeviceNet 5 Pin 

Field Terminal Block 

Modbus RTU -Any standard EZ Remote IO base model 

Modbus TCP/IP -Any Enhanced EZ Remote IO base model 

with Ethernet Option 

DeviceNet -An Optional DeviceNet Communication 

Module will be required along with the 


Profibus -An Optional Profibus Communication 

Module will be required along with the 


5 Pin Terminal Block 

11 Pin Terminal Block 

Dummy Module 

Accessories 

6 

Note: Cables to connect to the networks have not been shown here.


1.6 Part Numbering of the EZ Remote IO 

1 

2 

3 

Configuration Software 

EZ RIO-EDIT Software allows to configure the EZ Remote IO (one time purchase) 

Cable 

EZ PGMCBL Cable to connect the PC and Remote IO Base for EZ Remote IO 

configuration (one time purchase) 


Part Numbering System of the EZ Remote IO Base 

EZ RIO - X - XX - X 

Max I/O Supported 

4 Slots Base: 32 I/O Max 32 

Power Input 


110VAC 

A 


Enhanced 

24VDC 

D 


Built-in Ethernet TCP/IP 

E 

Example EZ RIO-D-32-E EZ Remote IO base with DC power, 32 I/Os and Ethernet option 

Following is the list of EZ Remote IO Base Part Numbers : 

Part Number EZ Remote IO Base Description 

EZ RIO-A-32 4-slot EZ Remote IO AC Powered; 32 I/O Max 

EZ RIO-A-32-E 4-slot EZ Remote IO AC Powered; 32 I/O Max; with built-in Ethernet 

EZ RIO-D-32 4-slot EZ Remote IO DC Powered; 32 I/O Max 

EZ RIO-D-32-E 4-slot EZ Remote IO DC Powered; 32 I/O Max; with built-in Ethernet 












EZ RIO-D-96-E 12-slot EZ Remote IO DC Powered; 96 I/O Max; with built-in Ethernet


1-9 

4 

5 

Communication Options 

EZRIO-DEVICENET 

EZRIO-PROFIBUS 

Optional DeviceNet Module 

Optional Profibus Module 

EZ I/O Modules 

Example EZIO-8DCI 8 point DC Inputs (sink/source) 

Following is the list of a variety of EZIO Part Numbers : 


DC Modules 

EZIO-8DCI 

EZIO-8DCOP 

EZIO-8DCON 

EZIO-8HSDCI 

EZIO-4DCI4DCON 

EZIO-4DCI4DCIF 

EZIO-4DCI4DCOP 

AC Modules 

EZIO-8ACI 

EZIO-8ACO 

EZIO-4ACI4ACO 

AC/DC Combo Modules 

EZIO-4DCOP4ACO 

EZIO-4ACI4DCOP 

EZIO-4DCI4ACO 

Analog Modules 

EZIO-8ANIV 

EZIO-8ANIC 

EZIO-4ANI4ANOV 

EZIO-4ANI4ANOC 

Relay Modules 

EZIO-4IORLO 

EZIO-4ACI4RLO 

EZIO-4DCOP4RLO 

Specialty Modules 

EZIO-4HSCM1 

EZIO-4HSCM2 

EZIO-4THI 

EZIO-4THIE 

EZIO-4RTD 

8 point DC Inputs (sink/source) 

8 point DC (source) Outputs 

8 point DC (sink) Outputs 

8 point High Speed DC Inputs (sink/source) 

4 point DC (sink/source) Inputs; 4 point DC (sink) outputs 

4 point DC (sink/source) Inputs; 4 point High Speed DC (sink/ 

source) Inputs 

4 point DC (Sink/Source) Inputs; 4 point DC (source) outputs 

8 point AC Inputs 

8 point AC Outputs 

4 point AC Inputs; 4 point AC Outputs 

4 point DC (source) Outputs; 4 point AC outputs 

4 point AC Inputs; 4 point DC (source) outputs 

4 point DC (sink/source) Inputs; 4 point AC Outputs 

8 channel Analog Input module (Voltage) 

8 channel Analog Input module (Current) 

4 Channel Analog Inputs; 4 Channel Analog Outputs 


4 point Relay Outputs 

4 point AC Inputs; 4 point Relay Outputs 

4 point DC (sink/source) Outputs; 4 point Relay Outputs 

High Speed 24-Bit Counter Module 

High Speed 24-Bit Counter Module 

4 Channel Thermocouple Input Module 

4 Channel Enhanced Thermocouple Input Module 

4 Channel RTD Input Module 

6 Accessories 

EZIO-DUMMY Dummy Module for Open Slots 

EZIO-TERM11 11 Pin Removeable 3.5mm Phoenix Terminal Block 

EZPLC-TERM5 5 Pin Removable 3.5mm Phoenix Terminal Block 

EZPLC -DNTERM5 DeviceNet 5Pin Field Terminal Block


1.7 Quick and EZ Start to Get Familiar with EZ Remote IO 

1.7 Quick and EZ Start to Get Familiar with 

EZ Remote IO 

In this section we present a quick example of how you can setup your EZ Remote 

IO. You will see how EZ it is to setup an EZ Remote IO, even if you are new to 

Remote IOs. This example is not intended to explain specific details needed to 

start-up your system. Rather, it provides a quick guide to give a broad picture of 

what is needed to power-up your EZ Remote IO system. 

Step 1 Check all System Components 

It is always recommended to make sure you have all the right parts 

to build your system. 

Step 2 Install I/O Modules 

Insert EZIO module(s) into the base. EZIO modules have a snap-on 

design to facilitate easy installation and removal from the base slots. 

The I/O modules have two clips and a Molex connector, which snap into 

the EZ Remote IO Base. 

• Hold the module in the thumb and index finger so that your fingertips 

are on the clips (see image to the left) 

• Snap the module onto the board so that clips are placed on the open 

slots 

• Make sure that the Molex connector is aligned to the female counter 

part on the base 

• Push the module gently from the top to insert it completely until 

you hear a clicking sound 

Step 3 Connect Power 

Connect the power input wires into the EZ Remote IO’s power 

terminals. Do not apply power at this time. 

Step 4 Install software on your PC 

Load the CD included with the purchase of software (P/N EZRIO-EDIT) 

into your computer’s CD-ROM drive and follow the on-screen 

instructions. The software will install itself. 

N OTE: If y o u 

p u r c h a s e d a n 

AC Power Base, 

everything else remains 

the same except for the 

use of 110 VAC in place 

of 24 VDC. 

Step 5 Connect EZ Remote IO to your PC 

Connect your PC’s serial port to EZ Remote IO’s RS232 port using the 

programming cable (P/N EZP-PGMCBL). 

Step 6 Switch ON the Power 

Apply power to the system and ensure the PWR indicator LED on the 

EZ Remote IO base is ON. If not, remove power from the system and 

check all wiring.


1-11 

Step 7 Create and Transfer a Configuration Project 

The EZ Remote IO application configures the Remote IO system 

by following the steps given below: 

1. Select the I/O Base 

2. Select the Network Type 

3. Place the module(s) onto the base 

4. Choose the communication port 

5. Transfer the configuration project to EZ Remote IO 

Congratulations! 

You have successfully configured your EZ Remote IO.


2 

Installation 

In This Chapter.... 

• EZ Remote IO Mounting 

-Base Mounting Dimensions 

• EZ Remote IO Base Wiring 

• EZIO Modules Positioning 

• EZIO Mounting and Wiring 

• Safety Considerations 

• Installation Considerations 

-General Environmental Considerations 

-Environmental Specifications 

-Agency Approvals 

-Physical Control Panel Layout 

• Electrical Considerations 

-Understanding of Electrical Noise, 

Optical Isolation, Wiring and Shielding 

-Cabinet Grounding 

-Cabinet Wiring 

-AC/DC Transient Protection 

-Filtering AC Line Noise 

-Isolating DC Power Supplies 

• Sourcing/Sinking Concepts 

D R A F T

2-2 


2.1 EZ Remote IO Mounting 

2.1 EZ Remote IO Mounting 

Safety is the most important element of a proper system installation. Adhering to these safety 

considerations ensures the safety of yourself and others, as well as the condition of your equipment. 

We recommend reviewing the following safety considerations: 

1) Disconnecting Main Power 

2) Safety Circuits 

3) Fail-Safe Operation 

Please follow all applicable local and national codes to ensure maximum safety of the equipment 

and personnel. The installation and operational environment must be maintained per the latest 

revision of these codes. You are responsible to determine the codes to be followed, and to verify 

the compliance of equipment, installation, and operation with the latest revision of these codes. 

Safety issues have also been discussed in detail in the later part of this chapter. 

Mounting Dimensions 

The diagrams on the following pages provide exact Base dimensions. The dimensions here 

represent the EZ Remote IO bases with I/O modules installed on them. However, it should 

be noted that EZ Remote IO offers flexibility to design your system based on your specific I/O 

requirements. So EZIO modules have to be purchased separately. EZIO has a snap-on design 

so that the I/O modules can be installed on the Base easily either before or after mounting the 

EZ Remote IO base. 

There is no limitation on I/O module location, except: 

1. The bottom left module cannot be AC Output or Relay module. 

2. Analog input and output combination module can be configured only in the first 4 slots. 

3. All Analog or Specialty modules can be configured only in the first 10 slots. 

Use 4/6 screws with STAR washers to secure the unit to the mounting surface. 

Pls refer to the table EZ I/O Module Position Restriction on the page 2-11 of this chapter. 

Dimensions of the EZ Remote IO bases are provided on the following pages, in inches and 

millimeters, mm appear in brackets [ ].

Chapter 2 - Installation 2-3 

EZ Remote IO base -4 Slots (32 I/O Model) 

Models: 

EZ RIO-A-32 

EZ RIO-A-32-E 

EZ RIO-D-32 

EZ RIO-D-32-E

2-4 



Models: 

EZ RIO-A-48 

EZ RIO-A-48-E 

EZ RIO-D-48 

EZ RIO-D-48-E



Models: 

EZ RIO-A-64 

EZ RIO-A-64-E 

EZ RIO-D-64 

EZ RIO-D-64-E

2-6 



Models: 

EZ RIO-A-96 

EZ RIO-A-96-E 

EZ RIO-D-96 

EZ RIO-D-96-E


2.2 EZ Remote IO Base Wiring 

Power Input 

24 Volts DC 

110 Volts AC 

Com1 Port 

Use the cable 

# EZ PGMCBL 

to configure the 

EZ Remote IO 


Enhanced EZ Remote IO base with 4-slots and maximum 32 I/O points 

DC AC 

L1 

L2 

+ - 

EZ RIO 

Power, CPU LEDs 

Slots 

(to place EZ I/O Modules) 

Ethernet Port 

(for Modbus TCP/IP network) 

(Only on EZ Remote IO base 

models with Ethernet Option) 

for DeviceNet Communication Option 

-Pls refer to the Chapter-3 

for Profibus Communication Option 

-Pls refer to the Chapter-4 

RS422 Port 

(for Modbus RTU network) 

Power Connection 

Power, CPU LEDs 

LED Color Comment 

PWR On (Red) Power is ON 

Off 

No Power to Unit 

CPU On (Green) CPU is scanning I/O 

Off 

CPU is NOT scanning I/O 

One of the two reasons: 

1. I/O may not be configured 

(Check the configuration by 

reading back from the unit) 

2. Hardware problem

2-8 


COM1 Port 

Pin Function 

2 TXD 

3 RXD 

5 GND 

9-Pin Sub-D 

Shield 

PC COM Port 

Pin Function 

2 RXD 

3 TXD 

5 GND 

9-Pin Sub-D 

Shield connected to 

Earth Ground on both sides 

RS232 Wiring Diagram 

* Terminal 1 is Logic Common 

DO NOT CONNECT TO PIN #1 

RS422 Wiring Diagram 

* 

SD- 

SD+ 

RD+ 4 

RD- 

Shield connected to 

Earth Ground on both sides 

1 

2 

3 

5 

EZ Remote IO


EZ Remote IO 1 

RS422 Port 

1 2 3 4 5 

GND SD- SD+ RD+ RD- 


RS422 Port 

1 2 3 4 5 


EZ Remote IO n 

RS422 Port 

1 2 3 4 5 


C 

O 

N 

T 

R 

O 

L 

L 

E 

R 

SD+ 

SD- 

RD+ 

RD- 

Modbus RTU Wiring 



EZ Remote IO n 

Ethernet Port 

Ethernet Port 

Ethernet Port 

C 

O 

N 

T 

R 

O 

L 

L 

E 

R 

Hub/Switch/Router 

Ethernet Connectivity

2-10 


2.3 EZIO Modules Positioning 

Slots Numbering System 

As discussed earlier there are 4 bases you can choose from: 4 slots, 6 slots, 8 

slots and 12 slots, that can support up to a maximum of 32, 48, 64 and 96 I/O 

points respectively. Use the following conventions to identify the slot numbers 

on the bases. 

CAUTION! The M2 slot 

cannot be used for any 

AC or Relay output module. 

Also, modules with 

both Analog inputs and 

outputs can be used only 

on slots M1 through M4 

and Analog and Counter 

modules in general must 

be used from M1 through 

M10. 

You can directly select an EZIO module and place it on a desired slot of the EZ 

Remote IO Base in the EZ Remote IO Software itself. The picture above shows 

the I/O module positioning convention employed in EZ Remote IO. Following 

are the guidelines/recommendations for installing I/O modules on an EZ Remote 

IO base. We have shown and described the 12-slots (capable of 96 I/O points 

MAX) base here; however the module numbering convention as well as the 

positioning guidelines remain the same for smaller bases.


EZ I/O Module Position Restrictions 


DC Modules 

EZIO-8DCI 

EZIO-8DCOP 

EZIO-8DCON 

EZIO-8HSDCI 

EZIO-4DCI4DCON 

EZIO-4DCI4DCIF 

EZIO-4DCI4DCOP 

AC Modules 

8 point DC Inputs (sink/source) 

8 point DC (source) Outputs 

8 point DC (sink) Outputs 

8 point High Speed DC Inputs (sink/source) 

4 point DC (sink/source) Inputs; 4 point DC (sink) outputs 

4 point DC (sink/source) Inputs; 4 point High Speed DC (sink/source) Inputs 

4 point DC (Sink/Source) Inputs; 4 point DC (source) outputs 

Recommendations for 

Positioning of Modules 

Any Slot 

EZIO-8ACI 8 point AC Inputs Any Slot 

Any Slot Except M2 

(will not fit over battery) 

EZIO-8ACO 8 point AC Outputs Any Slot Between M1 and M10 Except M2 

EZIO-4ACI4ACO 4 point AC Inputs; 4 point AC Outputs Any Slot Except M2 

AC/DC Combo Modules 

EZIO-4DCOP4ACO 4 point DC (source) Outputs; 4 point AC outputs Any Slot Except M2 

EZIO-4ACI4DCOP 4 point AC Inputs; 4 point DC (source) outputs Any Slot Except M2 

EZIO-4DCI4ACO 4 point DC (sink/source) Inputs; 4 point AC Outputs Any Slot Except M2 

Analog Modules 

EZIO-8ANIV 

EZIO-8ANIC 

EZIO-4ANI4ANOV 

EZIO-4ANI4ANOC 

Relay Modules 

EZIO-4IORLO 

EZIO-4ACI4RLO 

EZIO-4DCOP4RLO 

Specialty Modules 

8 channel Analog Input module (Voltage) 

8 channel Analog Input module (Current) 



4 point Relay Outputs 

4 point AC Inputs; 4 point Relay Outputs 

4 point DC (sink/source) Outputs; 4 point Relay Outputs 

Any Slot Between M1 and M10 Except M2 



EZIO-4HSCM1 High Speed 24-Bit Counter module Any Slot Between M1 and M10 Except M2 

EZIO-4HSCM2 High Speed 24-Bit Counter module 

3 Modules Max per Base 

EZIO-4THI 4 Channel thermocouple input module Any Slot Between M1 and M10 Except M2 

EZIO-4THIE Enhanced Thermocouple Module Any Slot from M1 to M10 

EZIO-4RTD Resistance Temperature Detector Any Slot from M1 to M10

2-12 


2.4 EZIO Mounting and Wiring 

EZIO Installation Overview 

EZIO modules are designed with one thing in mind - modularity! Any base of 

EZ Remote IO can be fitted with each and every EZIO module. All EZ Family 

Remote IOs are designed to handle any combination of EZIO modules without 

any need for power budgeting. Most EZIO modules consume only 20-40 mA 

current at 3.3V. 

Mounting I/O Modules 

EZIO modules have a snap-on design to facilitate easy installation and removal 

from the base slots. The I/O modules have two clips and a Molex connector, 

which snap into EZ Remote IO Base. 

EZIO Module Dimensions 

STEP 1 

STEP 1 - Hold the module in the 

thumb and index finger so that your 

fingertips are on the clips. 

STEP 2 

STEP 2 - Snap the module 

on the board so that clips are 

placed on the open mounting 

slots. Make sure that the 

Molex connector is aligned 

to the female counterpart 

on the base. Push the 

module gently from the top 

to insert it completely until 

you hear a clicking sound. 

Molex 

connector 

Mounting 

slot 

Wiring EZIO Modules 

As shown in the picture, simply insert the wire and screw to tighten. You can 

wire up to ONE 14 AWG wire, TWO 18 AWG wires, or FOUR 22 AWG wires in 

every terminal. You will need a 2.5mm blade screwdriver (P/N EZIO-SCDRV) 

to work with the EZIO terminal blocks and wiring. 

Routing EZIO Wiring 

EZIO modules have wiring trays for proper routing of field wires.


Number of Wires 

Allowed in Each Terminal 

1 14 AWG 

2 18 AWG 

4 22 AWG 

Wiring Capabilities 

UL rated at 300 volts, 

10 amps 14 AWG 

Discrete I/O Module Status Indicators 

The discrete I/O modules have LED status indicators to 

provide visual indication of the input points activity. 

Removable Terminal Blocks 

EZIO eliminates the need for rewiring your 

terminal block anytime you need to swap a 

module. Since these modules are built to 

withstand industrial environments, terminal 

blocks fit very snugly on the module. Slip the 

edge of the screwdriver under the terminal 

block and lift to pop it off. 

Removing I/O Modules 

- Hold the module in the thumb and index finger so that your 

fingertips are on the clips. 

- Apply inward pressure on the two clips with your fingers to 

release the module from the mounting slots on the base. 

- Pull the module out.

2-14 


2.5 Safety Considerations 

Please follow all applicable local and national codes to ensure maximum 

safety of the equipment and personnel. The installation and operational 

environment must be maintained per the latest revision of these codes. 

You are responsible to determine the codes to be followed, and to verify 

the compliance of equipment, installation, and operation with the latest 

revision of these codes. 

Plan for Safety 

It is an absolute must to follow all applicable sections of: 

• The National Fire Code 

• The National Electrical Code (NEC) 

• The National Electrical Manufacturer’s Association (NEMA) codes. 

Local regulatory and government offices usually provide excellent help to 

determine which codes and standards are necessary for safe installation 

and operation. 

Safety Techniques 

Safety is the most important element of a proper system installation. Adhering 

to these safety considerations ensures the safety of yourself and others, 

as well as the condition of your equipment. We recommend reviewing the 

following safety considerations: 

1) Disconnecting Main Power 

The main power switch should be easily accessible to the operators 

and maintenance personnel. It is important to make sure that all other 

sources of power including pneumatic and hydraulic are de-energized 

before starting the work on a machine or process controlled by a 

Remote IO. 

2) Safety Circuits 

Most of the machines are installed with safety circuits, like Limit 

switches, Emergency stop push buttons, and Interlocks. These circuits 

should always be hard-wired directly to the Remote IO. These devices 

must be wired in series so that when any one device opens, the Remote 

IO is automatically de-energized. This removes power to the machine. 

These circuits should not be altered in any case, since serious injury 

or machine damage could result. 

3) Fail-Safe Operation 

Our products are not fault-tolerant and are not designed or intended 

for use as on-line control equipment in hazardous environments requiring 

fail-safe performance, such as in operation of nuclear facilities, 

aircraft navigation or communication systems, air traffic control, direct 

life-support machines, weapons systems, clutch control systems on 

presses, in which the failure of the product could lead directly to death, 

personal injury or severe physical or environmental damage. External 

fail safe and/or redundant components are required to make your 

control system Fail-safe.


2.6 Installation Considerations 

EZAutomation products have been designed and tested for operation in the most demanding 

industrial environments. Modern solid-state industrial controls are complex electronic 

equipment that operate at low levels of voltage and current, coexisting with components that 

operate at much higher levels of power. The difference in operating power characteristics 

between the high and low power control devices creates the possibility of unwanted signals 

being generated causing interference. The interference, which is a by-product of electrical 

noise, is not present at all times. However, it appears at random and during brief periods 

of time it can cause disruptions and errors in the operation of a control system. 

Enhancement of a system’s noise level immunity, and its tolerance to other environmental 

hazards can be accomplished by following proper system installation guidelines. The 

recommendations are of a general nature and constitute good industrial installation 

practice. 

General Environmental Installation Considerations 

Avoid installing EZ Remote IO in areas where the following conditions may exist: 

• Environmental temperatures above or below those specified by the EZ Remote IO 

• Prolonged exposure to humidity and liquids which may be sprayed or splashed on the 

equipment 

• Dusty environments where airborne particles may accumulate on equipment causing 

reduction of heat dissipation, and reduction in effective electrical spacing between 

components 

• Areas of excessive vibration 

• Areas of high-radiated electrical noise, such as near fields of transmitting antennas 

and areas in close proximity of arc welding stations 

Environmental Specifications 

The following table lists the environmental specifications that generally apply to the 

EZ Remote IO Bases and EZIO modules. Please refer to the appropriate I/O module 

specifications in the EZIO User Manual (P/N EZIO-M). 

Parameter 

Operating Temperature -10 to 60 °C 

Storage Temperature -20 to 70 °C 

Humidity 

Vibration Resistance 

Shock Resistance 

Electrical Noise 

Atmospheric Conditions 

Ratings 

10 to 95% Relative Humidity, Non-condensing 

5 to 55 Hz, 2g for 2 Hours in X, Y, and Z Axes 

10g for under 12 ms in X, Y, and Z Axes 

NEMA ICS 2-230 Showering Arc, ANSI C37.90a SWC, Level C 

Chattering Test 

Non-corrosive gases

2-16 


Agency Approvals 

Your application may require Agency approval*. EZ Remote IO’s agency 

approvals are: 

• UL (Underwriter’s Laboratories, Inc)* 

• CUL (Canadian Underwriter’s Laboratories, Inc)* 

• CE (EU Certification)* 

• Approvals in process. Check our website www.EZAutomation.net for the 

latest information. 

Remote 

IO 

Physical Layout of EZ Remote IO In Control Cabinets 

When possible, cabinets housing electronic equipment should be designed with 

provisions for natural or forced ventilation to facilitate heat dissipation. Observe 

the following rules for cabinet installation: 

• Heat generating equipment (power supplies and other heat inducing 

components) should be installed toward the top of the cabinet. The lower 

space in the cabinet is cooler than the top area. 

• Install heat-sensitive components in the lower section. 

• Provide enough space between components to allow a free flow of air 

for better heat dissipation. 

• Provide the maximum possible physical separation between solid state 

and electromechanical controls. If possible, the electro mechanical 

controls (motors, starters, solenoids, etc.) should be housed separately 

or at the farthest point when enclosed within the cabinet. 

We recommend that the EZ Remote IO has a minimum clear space of 2” on 

all sides.


2.7 Electrical Considerations 

Understanding Electrical Noise, Optical Isolation, and 

Shielding of Cables 

This section will provide you with a very basic understanding of Electrical Noise 

and how to keep it away from CPUs. 

1. Source of Electrical Noise 

Industrial plants that have a number of generators of electrical noise are 

sometimes also referred to as Radio Frequency Interference or RFI. 

Any time an inductive load like a motor, motor starter, or solenoid is turned 

off, it generates a burst of excess energy that has to flow back to ground, 

just like electrical energy from a lightening storm has to flow back to Earth. 

Other sources are RF Welders or Radio Transmitters. RFI is short bursts 

of electrical energy at very high frequencies. 

2. Effect of RFI on Electronic Automation Equipment 

Electronic controls use faster and faster CPUs today. These CPUs are 

also operating at 2.5V to 5VDC logic level power supply. A CPU under 

this environment loses its brain and behaves erratically. A smart indus 

trial-grade CPU like the EZ Remote IO’s Card Engine, when faced with 

RFI, halts its operation instead of giving false outputs. 

3. How to Keep RFI Isolated from CPUs 

Cabinets 

Equipment cabinets usually incorporate one or two doors and/or hinged cabinet 

panels. In addition, sub-panels may be utilized on those electronic controls and 

electromechanical items that are mounted. 

The goal here is to create a medium for mounting the equipment and ensure 

grounding of the control’s chassis to it. Relying on door hinges and swinging 

panels for a good metallic bond between hinged parts and the main body of 

the cabinet does not insure adequate grounding. That is why the use of ground 

straps is recommended. 

RFI enters electronic controls in two ways: 

• Radiated RFI 

• Conducted RFI 

For most practical purposes, electronic devices, unless sitting right next to a 

powerful RFI transmitter, will not be affected by noise because air space severely 

attenuates such interference. On the other hand, conducted RFI travels 

over conductive surfaces such as power supply wires, electrical wiring of field 

devices, and worst of all; improper ground planes.

2-18 


Transformer or 

Choke Isolation 

Optical Isolation 

Remote IO 

Logic Level inside Dotted Lines 

Power Input 

Filter 

EZ Remote 

IO 

Power 

Supply 

CPU 

Card 

Engine 

Motherboard 

at Logic 

Level 

I/O 

Module 

I/O 

Module 

Transformer or 

Choke Isolation 

PC 

Optical Isolation 

It is a common practice with Remote IOs to isolate the sensitive CPU of the 

Remote IO from RFI by providing Transformer or Choke Isolation on the 

Power Supply and optical isolation at the I/O side. EZ Remote IO isolates 

the conducted RFI by both means, transformer/choke isolation as well as 

optical isolation for I/O modules. 

4. Cabling, Shielding, and Grounding 

It is vital for the reliable operation of any electronic device to have any 

of its metallic surface well grounded to Earth. This not only provides for 

safe operation, it also will drain out any conducted RFI to Earth, away from 

the CPU’s signal ground. Obviously, the metal cabinet housing the EZ 

Remote IO should also be well grounded. The following section will detail 

these procedures. 

Power cables, I/O cables or wiring and communication cables should all 

be separate so that they do not couple the conducted RFI on any of these 

wires/cables. Communication cables such as Ethernet, DeviceNet and 

Profibus cables have their own standards for noise isolation which must be 

followed. Another path for RFI into the EZ Remote IO is through its RS232 

and RS422/485 ports. The cables to these ports must be shielded properly 

as shown in the following diagrams.


Cabinet Grounding 

Equipment cabinets usually incorporate one or two doors and/or hinged 

cabinet panels. In addition, sub-panels may be utilized on those electronic 

controls and electromechanical items that are mounted. 

The goal is to create a medium for mounting the equipment and ensure 

grounding of the control’s chassis to it. Relying on door hinges and swinging 

panels for a good metallic bond between hinged parts and the main body 

of the cabinet does not insure adequate grounding. That is why the use of 

ground straps is recommended. 

Cabinet Door Grounding Straps 

The equipment enclosures are generally either painted or anodized. It is 

imperative that the equipment chassis are grounded. Not only is this good 

safety practice, but it also helps noise immunity problems. Mounting of 

painted or anodized enclosures to like surfaces does not insure good metallic 

contact between the equipment chassis and cabinet. 

The use of star washers when mounting the EZ Remote IO, or other 

components, provides sufficient grounding on the panel. 

Cabinet Chassis Grounding 

Star washers for proper grounding 

Cabinet Wiring 

The wiring of the EZ Remote IO to the “field” outside the cabinet must be 

by design. The wiring cannot be random in order to get the various points 

of the cabinet and the “field” electrically connected. 

Some general rules that apply in most situations: 

• Provide a separate power source to electronic controls and keep this 

power buss away from any I/O power. 

• The cabinet should be wired with a safety ground (the main safety 

ground wire gauge is determined by the cabinet’s total current 

consumption) and in accordance with all electrical code 

requirements. 

• Once the cabinet doors, stationary sub-panels and swing-out subpanels 

have been “strapped” to the main cabinet, it is not necessary to 

run safety ground wires from the equipment chassis terminals to the 

main safety ground connection. 

• The safety ground terminal of each component can, and should be, 

connected with the shortest wire possible, to the cabinet or sub-panel 

frame. 

• Plan the wiring routing. Keep all switched power in separate ducts and 

if there is AC and DC power being switched, keep the wiring of each 

branch separate from all wires and cables carrying low level signals. 

• Keep all three phase power outside of the cabinet, but if it becomes 

necessary, keep the runs as short as possible and maintain the maximum 

possible distance between the three phase buss and all other 

wiring. 

• Primary power leads to the control equipment (Base power 

terminals) should be made with a two wire twisted cable with 

approximately 12 turns per foot. The length of these cables should 

be kept to a minimum and to the greatest extent possible such 

cable runs should be kept separate from other wiring. 

• In the case of AC powered equipment, the primary power should be 

provided separately from the power source used for I/O control.

2-20 


AC/DC Transient Protection 

Recommended AC Inductive Transient Protection 

CAUTION! MOV 

should be 2 times 

the load voltage 

and have sufficient 

energy rating corresponding 

to the load. 

C A U T I O N ! D 1 

should have at least 

100 PIV and 3 Amp 

current capacity.Se 

cerum, vivendacret 

venductum 

AC Output Module 

C A U T I O N ! E Z 

Remote IO’s DC 

outputs have a builtin 

flyback diode to 

absorb an inductive 

kick. For this Diode to work 

effectively, the 24VDC power 

source powering the inductive 

load must be connected 

to the EZIO module. Use 

these recommended external 

suppressors for improved 

safety. 

Recommended DC Sinking Transient Protection 

DC Output Module


AC Line Noise 

The AC power available in house outlets and at sub-stations powering industrial 

and commercial applications is generally generated at a power station miles 

away from the point of usage. 

The power is “noise” free at the time it is being generated, and meets all 

specifications for amplitude, frequency, harmonic distortion and others. 

However, the same specifications cannot be guaranteed at the point of usage, 

due to the disruptive factors associated with the transmission from generator 

to consumer. 

While the generated power output starts its journey “clean,” and free of noise, 

it is “polluted” by radio and TV frequencies, spikes from reactive kickbacks due 

to switching heavy inductive and capacitive loads in transmission lines, and 

from other interference. 

As a result, critical and sophisticated electronic controls may malfunction; 

false triggering, user program loss and/or modification may occur and even 

catastrophic failure. 

In view of the problems associated with AC power, it is strongly recommended 

the source, transmission and final end use be given stringent consideration 

before any commitment to supply the system is given. Some typical problems 

in power line usage are: 

• Blackouts: 

• Brownouts: 

This is the total loss of power. Generally, they are easy to 

detect and if a situation arises where they cannot be tolerated 

then an un-interrupted power supply (UPS) should be used. 

This occurs when there is a reduction in line voltage 

amplitude. If this reduction falls within operating limits no 

adverse effects will be experienced. However, if they 

are frequent and severe,a UPS system should be considered. 

• Voltage 

Fluctuations: 

These are amplitude variations (rapid or slow) and can occur 

above or below the specified limits. Over-voltage conditions 

may damage equipment if the duration of the voltage 

condition is lengthy. It may cause disruptions, data loss, and 

production down-time. 

• Noise 

Spikes: 

Noise spikes and other unwanted signals superimposed on 

the AC line voltage waveform are the most common problems 

associated with the distribution of the power from its grid system. 

The amplitude of these signals can be from several hundred 

to a few thousand volts and the pulse width from about one to 

200 microseconds. Beacuse of their short duration and random 

occurances, these harmful signals are difficult to detect.

2-22 


Power connection 

+ _ 

DC AC 

L1 

L2 

Dealing with AC Line Noise 

The best option to effectively eliminate or greatly reduce voltage 

fluctuations, spikes and line noise is through the use of isolation, constant 

voltage or power line conditioner transformer. 

Isolation transformers are passive devices that do not have DC paths 

between the circuits they isolate. The transformer provides attenuation to 

spikes and common mode noise, but has virtually no effect on transverse 

mode noise and does not provide protection for voltage fluctuations. 

Constant voltage transformers are static Ferro-resonant transformers 

that can accept fluctuating AC voltage input (within a specified range) 

and maintain a constant voltage output. The transformers provide good 

attenuation to transverse mode type noise, however, are ineffective for 

attenuation of common mode type signals. 

Power line conditioning transformers provide good line regulation and are 

effective in providing attenuation to both common and transverse mode 

types of noise. 

CAUTION! Do not apply 

AC power to DC 

models. Do not apply 

220VAC to AC models. 

All of the mentioned transformer types are available by various 

manufacturers and they come in different varieties of operating voltages, 

power ratings, and frequencies. 

CAUTION! Keep the 

signal GND for CPU 

Power and I/O Power 

isolated. 

NOTE: Industrial Power 

Supplies today are relatively 

inexpensive. Any good 

industrial DC Power Source has an 

EMI filter built-in. An I/O DC Power 

Supply does not have to be that well 

regulated on the other hand. 

AC Power Distribution


DC Powered EZ Remote IO System 

If you are using 24VDC for DC Power for the EZ Remote IO, we recommend that the power 

for the CPU (Card Engine) be a separate Power Supply and the power source for DC Loads 

be a DC Load supply. 

The Power Cable Ferrite Core is a solid ferrite cylinder. The Power Cable should pass once 

through the core, be looped around and pass through a second time. Pull the excess cable 

so that it rests snugly against the outside of the core. 

Power Terminals 

Power Cable 

1” 

max 

Ferrite 

Cylinder 

You will come across these two terms quite often in the world of automation controls. This 

section will give you a short explanation and a simple way to remember the terminology. 

Source (P type) Sources Voltage to the receiver 

Source (N type) Sinks current through the load into GND

2-24 


2.8 Sourcing (P type) and Sinking (N type) I/O 

NOTE: A sourcing 

output sources/ 

supplies positive voltage 

to a load. 

Sources/Supplies 

Positive Voltage 

to Load 

(10-28 VDC) 

DC OUTPUT [SOURCE] 

NOTE: A sourcing 

input expects positive 

voltage for it to activate. 

Sources/Supplies 

Positive Voltage 

to Input


NOTE: A sinking output 

sinks/receives current from 

a load. 

Sinks/ 

Receives 

Current 

through 

the Load 

(10-28 VDC) 

DC OUTPUT [SINK] 

NOTE: A sinking input 

sends/sinks current to an 

external switch/output. 

Sinks 

Current to 

Field Output

3 

Chapter 3 - DeviceNet Configuration and Installation 

DeviceNet Configuration 

and Installation 



-Product Overview 

-Introduction to DeviceNet 

• Installation and Wiring 

-Installing the DeviceNet Module (EZ Remote IO) 

-Wiring the DeviceNet Module 

-Network Status LED 

• DeviceNet Module Configuration 

-EZ Remote IO Software 

-Adding EZ Remote IO to the DeviceNet Network 

-EDS File Contents

3-2 

DeviceNet Configuration and Installation 


3.1.1 Product Overview 

The DeviceNet option allows EZAutomation product-EZ Remote IO to act 

as a slave node on a DeviceNet network with a Master DeviceNet scanner 

module. The DeviceNet interface allows you to exchange data between 

the EZ Remote IO and DeviceNet Scanner. 

Product DeviceNet Availability Part Number 

EZ Remote IO 

Field installable Option 

Module 

EZ RIO-DEVICENET 

DeviceNet option on this product supports following: 

• MAC-ID 0-63 

• Baud Rate 125KB, 250KB or 500KB with 500 m. 250m, and 100m 

maximum bus length, respectively. 

• I/O messaging, Polled Mode only 

• Ability to produce and consume up to 254 Bytes each. 

3.1.2 Introduction to DeviceNet 

DeviceNet, probably the most popular device level bus, is an open network 

standard for field devices. A variety of devices from several vendors are 

available for DeviceNet. The ODVA (Open DeviceNet Vendors Association), 

an organization of vendors, regulates the DeviceNet Standard. See www. 

odva.org for information on DeviceNet. 

ODVA, a vendor association, 

m a i n t a i n s D e v i c e N e t 

Standards. Visit their site for 

more information on DeviceNet 

www.odva.org The site has 

a wealth of information on 

DeviceNet 

DeviceNet is a device level communication link that connects industrial 

devices, such as limit switches, photoelectric sensors, proximity sensors, 

valve manifolds, motor starters, process sensors, bar code readers, variable 

frequency drives, panel displays, and operator interfaces to a common 

network. 

Networking of devices eliminates the necessity for expensive hard wiring, 

and the resulting testing and maintenance that goes with it. It also reduces 

the cost and time needed to wire and install automation devices, while 

providing improved communication between devices, as well as important 

device-level diagnostics not easily accessible or available through hard 

wired I/O interfaces. Networks such as DeviceNet allows interoperability 

of devices manufactured by different vendors.

DeviceNet Configuration and Installation 3-3 

3.2 Installation and Wiring 

3.2.1 Installing the DeviceNet Module (EZ Remote IO) 

The DeviceNet Option Module package for EZ Remote IO contains the following: 

1. DeviceNet Options Module 

2. DeviceNet plug-in connector 

3. Nylon spacer and two nylon screws 

To install the DeviceNet Module into your EZ Remote IO, perform the following steps: 

Screw 1 

1. Place Screw 1 into the hole on the DeviceNet Module and thread 

it through the spacer on the other side. Next, position the module 

over the back of the EZ Remote IO so that the holes for the fasten 

-ing screws are lined up. 

Spacer 

Mating 

Connectors 

DeviceNet Option 

Module 

EZRemote IO 

Screw 2 

Make sure the pin and 

socket ends of this 

connector are lined up. 

2. You will have to angle the DeviceNet module to first feed the housing 

for the fastening screw through the hole provided in EZ Remote IO.

3-4 


3. Next bring the pin and socket ends of the connector together and 

firmly press them together. 

4. Once the DeviceNet Module is in place, tighten Screws to secure the 

module into position. 

DeviceNet Connector 

Screw 2 

The image below shows the top view of the EZ Remote IO with the 

DeviceNet Module properly installed. 

DeviceNet Connector


3.2.2 Wiring the DeviceNet Module 

To wire the DeviceNet Module to your EZ Remote IO, you must first connect 

the DeviceNet cable to the removeable connector attached to EZ Remote 

IO according to the diagram below. 

(• 

(• 

(• 

(• 

(• 

V- (black) 

CAN* Low (blue) 

Shield (bare) 

CAN* High (white) 

V+ (red) 

*Controller Area Network 

Removable DeviceNet Connector 

Table below shows maximum bus length for a given Baud rate:. 

Baud Rate Max Bus Length 

125KB 500 m 

250KB 250 m 

500KB 100m 

Please follow the DeviceNet guidelines for wiring. ODVA has a Planning 

and Installation guide on their site. 

3.2.3 Network Status LED 

After wiring the DeviceNet, you would need to program the DeviceNet parameters and then add the device to 

scanner list and commission the node. 

An indicator light is provided on the DeviceNet Module to see the Status of the module, as shown below, should 

you have any problems:

3-6 


The Network Status LED is a small colored light located near the removable DeviceNet Connector (see the 

yellow circle in the image to the left). The LED will display as OFF, GREEN, FLASHING GREEN, or RED 

depending on what it is indicating. A summary of the different LED states and what they indicate is provided in 

the table below: 

Combined Module/Network Status LED 

For this State: LED is: To indicate: 

Not powered/Not online 

Device Operational AND 

Online, connected 

Device Operational AND 

Online, Not Connected 

OR 

Device Online 

AND Device needs 

commissioning 

OFF 

GREEN 

FLASHING 

GREEN 

DeviceNet is not online 

- the device has not yet completed the Dup_MAC_ID test yet 

- the device may not be powered 

The device is operating in a normal condition and the device is 

online with connections in the established state. 

- the device has one or more established connections 

The Device is operating in a normal condition and the device is 

online with no connections in the established state. 

- the device has passed the Dup_MAC_ID test, is online, but 

has no established connections to other nodes 

- the device has no established connections 

Critical Fault 

OR 

Critical Link Failure 

RED 

The device has an unrecoverable fault and may need 

replacing. 

Failed communication device. The device has detected an error 

that has rendered it incapable of communicating on the network 

(Duplicate MAC ID, or Bus-off).


3.3 DeviceNet Module Configuration 

Once you have installed the DeviceNet card, you’ll need to configure it before you can use it. 

There are 2 things to configure: 

1. DeviceNet Network parameters: 

Use EZ Remote IO software to Program Node Address (0-63), Baud rate (125KB, 250KB or 500KB), 

Words consumed and the Words produced by the EZ Remote IO.EZ Remote IO allows you to produce up 

to 127 words (254 bytes) to send over the network, and consume up to 127 words or 254 bytes (get from 

the network). 

2. Scanner List and Node commissioning: 

You will need to add the module to the scan list of the scanner in the Network. You will need to use a 

software, such as RSNetworx that supports the scanner you are using. Please refer to the documentation 

of the scanner and the software it uses. 

3.3.1 EZ Remote IO Software 

DeviceNet Properties 

Note: The DeviceNet and 

Profibus settings can only be 

configured for Remote IOs 

with DeviceNet and Profibus 

communication interfaces 

installed. 

MAC-ID: 

0 to 63. Many users use 0 Mac 

ID for scanner. Each node on a 

network has a unique MAC-ID. 

Baud Rate 

DeviceNet supports 3 baud rates. 

Select the baud rate of your 

network: 

In EZ Remote IO Software, click onto the Select I/O Network. 

Under Select I/O Network , select DeviceNet. 

Next click on Edit Settings... 

The following dialog will appear: 

Consumed Words 

Up to 127 words (254 bytes), 

received from the network. 

Produced Words 

Up to 127 words (254 bytes), sent 

to the network. 

Use the above dialog box to program Mac-ID, Consumed Words, Produced 

Words, along with the Baud Rate. Please note that the Produced and Consumed 

word fields are specified in Words units (2 bytes each), and not in Bytes. (If your 

scanner setup software requires this information in bytes, please multiply the count 

by two.) 

EZ Remote IO allows you to produce up to 127 words (254 bytes) to send over the

3-8 


3.3.2 Adding Remote IO to the DeviceNet Network 

EDS file name: AVG_EZ Remote 

IO.EDS 

(see next page for file content). 

The dialog box below shows the 

properties of the EZ Remote IO 

DeviceNet interface. Since the 

same DeviceNet module is used 

in our HMI and other products, it is 

only listed under the HMI category 

in RSNetworx. 

Once the EZ Remote IO is all configured ( the network parameters), you 

can add it to the DeviceNet Network. 

The procedure to add the EZ Remote IO to the network depends upon the 

scanner and its Network configuration software. 

In general, you will take following steps: 

1. Register the EDS file in the Network configuration software. 

2. Add the Remote IO to the scan list of the scanner, and map the scanner 

memory to EZ Remote IO’s devicenet module. 

3. Go online. 

The dialog boxes below show examples of adding the EZ Remote IO to an 

AVG DeviceNet Scanner using RSNetworx software. 

The dialog box to the left is used to define the Rx and Tx 

sizes. These must match with the size of the area defined 

in the EZ Remote IO Editor for Produced and Consumed 

words, respectively. Please note that in the EZ Remote IO 

editor the sizes are defined in words, while here the sizes 

are defined in bytes. Please multiply the number of words 

by 2 to get the correct number. 

Rx in Scanner = Produced in EZ Remote IO 

Tx in Scanner = Consumed in EZ Remote IO


3.3.3 EDS File Content 

The CD contains the EDS file for the DeviceNet Option Module. The file is 

called AVG_EZ Remote IO.EDS. The content of this file is listed below: 

[File] 

DescText = “EZ Remote IO Series”; 

CreateDate = 01-03-2005; 

CreateTime = 14:43:15; 

ModDate = 01-03-2005; 

ModTime = 00:00:00; 

Revision = 1.0; 

[Device] 

VendCode = 39; 

VendName = “AVG Automation (Uticor)”; 

ProdType = 24; 

ProdTypeStr = “EZ Remote IO Series”; 

ProdCode = 21; 

MajRev = 1; 

MinRev = 1; 

ProdName = “EZ Remote IO Series”; 

Catalog = “EZP-”;

4 

Chapter 4 - Profibus Configuration and Installation 

Profibus Configuration 

and Installation 



-Product Overview 

-Introduction to Profibus 

• Installation and Wiring 

-Installing the Profibus Module (EZ Remote IO) 

-Wiring the Profibus Module 

-Network Status LED 

• Profibus Module Configuration 

-EZ Remote IO Software 

-Adding EZ Remote IO to the Profibus Network 

-GDS File Contents 

D R A F T

4-2 

Profibus Configuration and Installation 


4.1.1 Product Overview 

The Profibus option allows EZAutomation product-EZ Remote IO to act as 

a slave node on a Profibus network with a Master Profibus module. The 

Profibus DP interface allows you to exchange data between the EZ Remote 

IO and master PLC’s and their I/O. 

Product DeviceNet Availability Part Number 

EZ Remote IO 

Field installable Option 

Module 

EZ RIO-PROFIBUS 

Profibus option on these products supports following: 

• 125 Addressable Nodes 

• Auto Baud 

• Up to 244 bytes of Input and up to 244 bytes of outputs 

4.1.2 Introduction to Profibus 

Profibus DP operates as a master slave system. It usually consists of a 

single master and from 1 to 125 slaves. A variety of devices from several 

vendors are available for Profibus DP. An organization of vendors regulates 

the Profibus Standard. 

Profibus DP (Decentralized Peripherals) has been designed for fast data 

exchange at field level. This is where central programmable controllers, such 

as PLCs, PCs or process control systems, communicate with distributed 

field devices, such as I/O, drives, valves, transducers or analysis devices, 

panel displays, and operator interfaces over a fast serial connection. 

Every Profibus DP device has a Device Master File (GSD File) associated 

with it. This file contains detailed information about the device, including: 

I/O data size, comm rates supported, revision, etc. To configure a station 

within a Profibus DP system a GSD File for that station is required. This 

file is located on the CD. 

4.2 Installation and Wiring 

4.2.1 Installing the Profibus Module (EZ Remote IO) 

The Profibus Option Module package for EZ Remote IO contains the following: 

1. Profibus Options Module 

2. Profibus plug-in connector 

3. Nylon spacer and two nylon screws

Profibus Configuration and Installation 4-3 

Screw 1 

To install the Profibus Module into your EZ Remote IO, perform the following 

steps: 

1. Place Screw 1 into the hole on the Profibus Module and thread it through 

the spacer on the other side. Next, position the module over the back of 

the EZ Remote IO so that the holes for the fastening screws are lined up. 

Spacer 

Mating 

Connectors 

Screw 

Profibus Option Module 

2. You will have to angle the Profibus module to first feed the housing 

for the fastening screw through the hole provided in EZ Remote IO. 

EZ Remote IO 

Make sure the pin and 

socket ends of this 

connector are lined up.

4-4 


3. Next bring the pin and socket ends of the connector together and 

firmly press them together. 

4. Once the Profibus Module is in place, tighten Screws to secure the 

module into position. 

Screw 2 

Profibus Connector 

The image below shows the top view of the EZ Remote IO with the 

Profibus Module properly installed. 

Profibus Connector


4.2.2 Wiring the Profibus Module 

Profibus Connector 

To wire the Profibus Module to your EZ Remote IO, you must first connect 

the Profibus cable to the connector attached to EZ Remote IO according 

to the diagram below. 

9-way D-type 

Pin 1 

Pin 2 

Pin 3 

Pin 4 

Pin 5 

NC 

NC 

B line 

Request to send (RTS) 

Ground 5V (M5) 

Pin 6 Potential 5V (floating P5) 

Pin 7 

Pin 8 

Pin 9 

NC 

A line 

NC 

Please refer to the Profibus standard for maximum bus length 

permissable between stations. 

4.2.3 Network Status LED 

After wiring the Profibus, you would need to set the Profibus parameters.An indicator light is provided on 

the Profibus Module to see the Status of the module, as shown below, should you have any problems: 

The Network Status LED is a small colored light located on the back of the module (see the yellow circle in the 

image to the left). The LED will display as OFF or RED depending on what it is indicating. A summary of the 

two LED states and what they indicate is provided in the table below: 

Combined Module/Network Status LED 

For this State: LED is: To indicate: 

Unit OK OFF Board configured and communicating over Profibus 

Critical Fault 

OR 

Critical Link Failure 

RED 

The device has an unrecoverable fault and may need 

replacing. 

Failed communication device. The device has detected an error 

that has rendered it incapable of communicating on the network 

(Duplicate MAC ID, or Configuration error).

4-6 


4.3 Profibus Module Configuration 

Once you have installed the Profibus card, you’ll need to configure it 

before you can use it. There are 2 things to configure: 

1. Profibus Network parameters: 

Program Node Address (1-125). The module adjusts baud rate 

automatically. 

Use EZ Remote IO software to initially program these. 

2. Scanner List and Node commissioning: 

You will need to add the module to the scan list of the scanner in 

the Network. You will need to use a software, such as Siemens 

configuration tool that supports the scanner you are using. Please 

refer to the documentation of the scanner and the software it uses. 

4.3.1 EZ Remote IO Software 

Profibus Properties 

In EZ Remote IO Software, click onto the Select I/O Network. 

Under Select I/O Network, select Profibus... 

The following dialog will appear: 

Note: The Profibus settings 

can only be configured 

for EZRemote IOs with 

Profibus communication 

interfaces installed. 

When Profibus is selected, click on Edit Settings. The dialog box 

Node Address: 

1-125. Each node on a network 

has a unique MAC-ID. 

Input Words 


received from the network. 

Output Words 


sent to the network. 

Use the above dialog box to program Node Address, Input Words, 

and Output Words. Please note that the Input and Output word fields 

are specified in Words units (2 bytes each), and not in Bytes. (If your 

scanner setup software requires this information in bytes, please multiply 

the count by two.) EZ Remote IO allows you to produce up to 122 words 

(244 bytes) to send over the network, and consume up to 122 words or 

244 bytes (get from the network).


4.3.2 Adding EZ Remote IO to the Profibus Network 

GSD file name: AVG09BC.gsd 

(see next page for file content). 

Once the EZ Remote IO is all configured ( the network parameters), you 

can add it to the Profibus DP master or slave Network. 

The procedure to add the EZ Remote IO to the network depends upon 

the software tools being used. 

In general, you will take following steps: 

1. Register the GSD file in the Network configuration software. 

2. Add the Remote IO to the Profibus network matching the parameters 

set in the EZ Remote IO network configuration. 

3. Go online. 

The dialog boxes below and on the next page show an example of 

adding the EZ Remote IO to a Profibus network using Siemens Step 7 

Programming Software. 

The dialog box to the right 

shows the Siemens Step 7 

software when launched. 

Select your project from the 

left window. Then double 

click on Hardware to start 

configurating your hardware 

to add EZ Remote IO. 

The dialog box to the right shows 

the top portion of the hardware 

configuration. 

Select the Options menu, then 

select Install GSD file... 

You will need to copy and paste 

the contents of AVG09BC.gsd file 

from your EZ Remote IO CD or 

from your computer’s EZ Remote 

IO folder.

4-8 


The dialog box to 

the right shows that 

EZAutomation is 

now in the Profibus 

catalog list in the 

right window of the 

sotware. You can 

simply drag the 

EZAutomation_DP 

name to the center 

window under the 

line and drop to 

connect the EZ 

Remote IO to your 

Profibus network. 

The dialog box to 

the right shows 

that after adding 

EZ Remote IO to 

the network, open 

the listing under 

EZAutomation to 

view the available 

inputs and outputs 

for your EZ Remote 

IO. Drag the inputs 

or outputs to the 

bottom window 

table to add the 

I/O.


4.3.3 GSD File Content 

The CD contains the GSD file for the Profibus Option Module. The file is 

called AVG09BC.gsd. The content of this file is listed below: 

;===================================================== 

; Profibus Device Database of : 

; EZAutomation_DP slave 

; Model : EZAutomation_DP 

; Description : EZAutomation_DP Profibus DP slave 

; Language : English 

; Created : 24 MAY 2005 

; Author : AVG_UTICOR 

; 

; MODIFICATIONS: 

; 

;===================================================== 

#Profibus_DP 

GSD_Revision = 1 

; Device identification 

Vendor_Name = “AVG_UTICOR” 

Model_Name = “EZAutomation_DP “ 

Revision = “Version 1.0” 

Ident_Number = 0x09BC 

Protocol_Ident = 0 ; DP protocol 

Station_Type = 0 ; Slave device 

FMS_supp = 0 ; FMS not supported 

Hardware_Release = “Version 1.0” 

Software_Release = “Version 1.0” 

; Supported baudrates 

9.6_supp = 1 

19.2_supp = 1 

45.45_supp = 1 

93.75_supp = 1 

187.5_supp = 1 

500_supp = 1 

1.5M_supp = 1 

3M_supp = 1 

6M_supp = 1 

12M_supp = 1 

; Maximum responder time for supported baudrates 

MaxTsdr_9.6 = 60 

MaxTsdr_19.2 = 60 

MaxTsdr_45.45 = 250 

MaxTsdr_93.75 = 60 

MaxTsdr_187.5 = 60 

MaxTsdr_500 = 100 

MaxTsdr_1.5M = 150 

MaxTsdr_3M = 250 

MaxTsdr_6M = 450 

MaxTsdr_12M = 800

4-10 


; Supported hardware features 

Redundancy = 0 ; not supported 

Repeater_Ctrl_Sig = 2 ; TTL 

24V_Pins = 0 ; not connected 

Implementation_Type = “SPC3” 

; Supported DP features 

Freeze_Mode_supp = 1 ; supported 

Sync_Mode_supp = 1 ; supported 

Auto_Baud_supp = 1 ; supported 

Set_Slave_Add_supp = 0 ; not supported 

; Maximum polling frequency 

Min_Slave_Intervall = 1 ; 100 us 

; Maximum supported sizes 

Modular_Station = 1 ; modular 

Max_Module = 24 

Max_Input_Len = 244 

Max_Output_Len = 244 

Max_Data_Len = 416 

Modul_Offset = 1 

Fail_Safe = 0 ; state CLEAR not accepted 

Slave_Family = 0 

Max_Diag_Data_Len = 6 

; Definition of modules 

Module = “INPUT: 1 Byte” 0x10 

EndModule 

; 

Module = “INPUT: 3 Byte” 0x13 

EndModule 

; 

Module = “INPUT: 2 Byte ( 1 word)” 0x50 

EndModule 

; 


EndModule 

; 


EndModule 

; 


EndModule 

; 

Module = “INPUT: 32 Byte (16 word)” 0x5F 

EndModule 

; 

Module = “INPUT: 64 Byte (32 word)” 0x40,0x5F 

EndModule 

;


Module = “OUTPUT: 1 Byte” 0x20 

EndModule 

; 

Module = “OUTPUT: 3 Byte” 0x23 

EndModule 

; 

Module = “OUTPUT: 2 Byte ( 1 word)” 0x60 

EndModule 

; 


EndModule 

; 


EndModule 

; 


EndModule 

; 

Module = “OUTPUT: 32 Byte (16 word)” 0x6F 

EndModule 

; 

Module = “OUTPUT: 64 Byte (32 word)” 0x80,0x5F 

EndModule

Index 

Symbols 

Index 

I-1 

A 

AC/DC Transient Protection 2-20 

Accessories 1-6,1-8 

AC Line Noise 2-22 

Adding EZ Remote IO to the DeviceNet Network 3-1 

Adding EZ Remote IO to the Profibus Network 4-1,4-7 

Agency Approvals 2-1,2-15,2-16 

Autotech 1-2 

B 

Base Mounting Dimensions 2-1 

Base Wiring 2-1,2-7 

Baud Rate 3-5,3-7 

Blackouts 2-21 

Brownouts 2-21 

C 

Cabinet Grounding 2-19 

Cabinet Wiring 2-19 

Cable 1-6,1-7 

Cabling 2-18 

CAN 3-5 

Choke Isolation 2-18 

Com1 Port 2-7 

Communication Link 1-4 

Components of the EZ Remote IO System 1-7,1-6 

Configuration S/W 1-6 

Configuration Software 1-7 

Connect Power 1-9 

Consumed Words 3-7 

Controller Area Network 3-5 

Critical Fault 3-6,4-5 

Critical Link Failure 3-6,4-5 

D 

DC Powered EZ Remote IO System 2-23 

DC Sinking Transient Protection 2-20 

DeviceNet 1-4,1-5,1-6,1-4,1-5,1-8 

DeviceNet Module 3-3

I-2 

DeviceNet Module Configuration 3-1,3-7 

DeviceNet Parameters 3-7 

Disconnecting Main Power 2-2,2-14 

Dummy Module 1-6,1-8 

Dup_MAC_ID 3-6 

Duplicate MAC ID 3-6 

E 

EDS File Contents 3-1 

Electrical Considerations 2-1,2-17 

Electrical Noise 2-1,2-15,2-17 

Enter Program 1-10 

Environmental Specifications 2-15 

Environmental Specifications vi 

Ethernet Connectivity 2-9 

Ethernet Port 2-7,2-9 

EZAutomation 1-2,1-3 

EZIO Installation Overview 2-7,2-12 

EZIO Modules Positioning 2-1,2-10 

EZIO Module Dimensions 2-12 

EZIO Mounting and Wiring 2-1,2-7,2-12 

EZ Remote IO In Control Cabinets 2-16 

EZ Remote IO Mounting 2-2 

EZ I/O Modules 1-8 

EZ I/O Module Position Restrictions 2-11 

EZ Remote IO 1-4 

EZ Remote IO Base 1-6,1-7,1-9 

EZ Remote IO Base Wiring 2-1,2-7 

EZ Remote IO Mounting 2-1,2-2 

EZ Remote IO Software 3-1,3-7 

EZ Remote IO Specifications 1-7,1-5 

EZ Remote IO System Overview 1-7,1-4 

EZ RIO-M 1,iv 

F 

Fail-Safe Operation 2-2,2-14 

Filtering AC Line Noise 2-1 

G 

GDS File Contents 4-1 

Grounding 2-18 

GSD File Content 4-9

I-3 

I 

Input Words 4-6 

Installation Considerations 2-1,2-15 

Installing the DeviceNet Module 3-3 

Installing the Profibus Module 4-1,4-2 

Install I/O Modules 1-9 

Introduction 1-2,2-2,3-2 

Introduction to DeviceNet 3-2 

Introduction to Profibus 4-2 

Isolating DC Power Supplies 2-1 

L 

LED 2-7,2-13 

M 

MAC-ID: 3-7,4-6 

Mating Connectors 3-3,4-3 

Memory Mapping 

Modbus RTU 1-4 

Modbus RTU Wiring 2-9 

Modbus TCP/IP 1-4,1-6,1-4,1-5 

Mounting Dimensions 2-2 

N 

Network parameters 3-7,4-6 

Network Status LED 3-1,3-5,3-6,4-5 

Network Type 1-10 

Node commissioning 3-7,4-6 

Noise Spikes 2-21 

O 

Optical Isolation 2-1,2-17,2-18 

Output Words 4-6 

P 

Part Number 1-5,1-7 

Patent No 1-2 

Physical Control Panel Layout 2-1 

Power, CPU LEDs 2-7 

Power Cable Core 2-23

I-4 

Power Connection 2-7 

Power connection 2-22 

Power Input 2-7,2-18 

Preventative Maintenance and Cleaning vi 

Produced Words 3-7 

Product Overview 3-2,4-2 

Profibus. 1-4 

Profibus Module 4-3 

Profibus Module Configuration 4-1,4-6 

Profibus Parameters 4-6 

Purpose of the Manual 1-3 

R 

Removable DeviceNet Connector 3-5 

RFI on Electronic Automation Equipment 2-17 

RS232 Wiring Diagram 2-8 

RS422 Port 2-7,2-9 

RS422 Wiring Diagram 2-8 

Rx in Scanner 3-8 

S 

Safety 2-14 

Safety Circuits 2-2,2-14 

Safety Considerations 2-1,2-14 

Safety Techniques 2-14 

Scanner List 3-7 

Select Network Type 3-7 

Shield 3-5 

Shielding 2-18 

Shielding of Cables 2-17 

Sinking (N type) 2-24 

Slots 2-3,2-4,2-5,2-6,2-7,2-10 

Slots Numbering System 2-10 

Sourcing/Sinking Concepts 2-1 

Sourcing (P type) 2-24 

System Components 1-9 

T 

Table of Contents 1-3 

Technical Support 1-7,1-3 

Tx in Scanner 3-8

I-5 

U 

Uticor 1-2 

V 

V+ 3-5 

V- 3-5 

Voltage Fluctuations 2-21 

W 

Wiring 3-5 

Wiring Capabilities 2-13 

Wiring the DeviceNet Module 3-1,3-5 

Wiring the Profibus Module 4-1,4-5 

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