H Unit

Input/Output
Manual

4 4
INPUTS OUTPUTS

RS485
 Table of Contents
Safety Rules .........................................Inside Front Cover
1.1 Introduction .................................................IFC
2.1 Communications ..........................................IFC
2.2 Baud Rate ....................................................IFC
2.3 Modbus Address ............................................. 1
2.4 Speed of Response .......................................... 1
2.5 Communications Failure ................................. 1
3.1 Programming................................................... 1
3.2 Communications Settings ................................ 1
3.3 HUIO Configuration ......................................... 1
3.4 Setting Up the Inputs ...................................... 2
3.5 Setting Up the Outputs .................................... 2
4.1 Input Specifications ......................................... 2
5.1 Output Specifications ...................................... 2
6.1 Power and Communications Connections ....... 2
7.1 Quick Setup .................................................... 3
8.1 Diagnostic Monitor .......................................... 4
1.1 INTRODUCTION
The HUIO module is designed to connect to an H-
panel (ONLY) and expand it’s input and output capa-
bility. Each HUIO module has four (4) inputs and four
(4) outputs. Up to four (4) modules can be attached
to the H-panel to give a total of 16 additional inputs
and 16 additional outputs. The state of the output
relays can be seen on the PCB Led’s 1-4.
The additional Input/Output will appear to be a con-
tinuation of the existing Input/Output and will adopt
all of it’s properties such as channel naming, alarms,
ILC visibility etc.
The HUIO will connect to an H-panel via the simple
3-wire RS485 interface along with other peripherals
such as HTS Transfer Switches, Remote Annunciators
and Remote Relay panels. Because we are using
RS485, the HUIO can be located up to 4000 feet away
from the H-panel (depending on site and configura-
tion).
2.1 COMMUNICATIONS
The HUIO will connect onto the RS485 bus as a
Modbus slave, along with any optional HTS units and
remote annunciators/remote relay boards.
2.2 BAUD RATE
The following baud rates are available - 4800, 9600,
38400, 57600. The baud rate for the RS485 port is
set on the H-panel. At power up, the HUIO module
will automatically search for the correct baud rate.
If no good communications are received within three
seconds, the HUIO will change it’s baud rate on a
cyclical basis. The baud rate search starts at 4800
baud. Once good communications are established,
the baud rate will be held for two time-out periods
even if the communications go bad. This is to pre-
vent minor noise from causing the baud rate to cycle.
Similarly outputs are disabled after one or two time-
out periods depending if communications were ever
established. The baud rate does not affect the speed
of response (see section "Speed of Response").
 H Unit Input/Output Manual

2.3 MODBUS ADDRESS 2.5 COMMUNICATIONS FAILURE

Each HUIO has base Modbus address of 230 plus a
unique address which is set by two dip switches on
the module (see Table 1), giving a total of four possible
options 230-233. The H-panel has to be programmed
via Genlink (NOT THE FRONT PANEL) as to which
modules are connected (which addresses are in ser-
vice), i.e. it is not plug and play. The reason for this is
that the H-panel would need to continually search for
each unit, and each unit would be adjusting it’s baud
rate every three seconds. With the combination of
time-outs and slow loop times, the bus would become
sluggish, the baud rate continually changing, and we
may never achieve a connection.
Input and output designation is fixed by module
address:
Table 1
ADDRESS SW1 SW2
In the event that communications to a HUIO fail,
a warning will be posted on the front of the H-
panel. The warning WILL NOT SHUT DOWN THE
GENERATOR. The HUIO inputs will be set to a
known condition (0 or “OFF”) and the outputs will
turn themselves off. This process will take between
1.5 – 7.2 seconds. For example if there are four
HUIO’s the H-panel will only access any one at 2.4
second intervals at which time it will send both a
read and a write message. The H-panel needs to see
five missed messages before it confirms a failure, so
it will take up to three intervals to make six message
attempts, or, 7.2 seconds (3* 2.4 seconds).
Figure 1 — Communications Failure
First read & Second read & Third read &
write message write message write message
to HUIO1 to HUIO1 to HUIO1

230 0 0 Contains inputs 12-15 and

outputs 17-20 START

231 0 1 Contains inputs 16-19 and

outputs 21-24 2.4s 2.4s 2.4s

232 1 0 Contains inputs 20-23 and

outputs 25-28
233 1 1 Contains inputs 24-27 and
outputs 29-32
2.4 SPEED OF RESPONSE
HUIO’s are serviced cyclically with two messages (read
and write) sent to each connected HUIO in turn. The
message length is very small so the speed of response
is not affected by the baud rate. For example four
units require eight messages. Each message is sepa-
rated from the next by 300ms so each HUIO requires
600ms to be serviced. This results in a response time
roughly equal to:
• 600ms * number of HUIO’s
Thus the worst case response time after the auto
baud rate algorithm has established a connection is:
• 600ms * 4 = 2.4 seconds
Any time critical Input/Output should be programmed
to be on the original H-panel inputs and outputs as
they have an almost instantaneous response.
3.1 PROGRAMMING
Genlink needs to be used to program the functions of
the individual channels such as alarms, alarm prop-
erties, channel naming etc.. It is too complex to be
done from the front panel.
3.2 COMMUNICATIONS SETTINGS
Using Genlink, go to the communication port configu-
ration page and set the RS485 port to be a Modbus
master. Choose one of the four required baud rates
(4800, 9600, 38400, 57600). If an old style remote
annunciator is fitted the communications must be set
at 4800 baud, no parity and two stop bits. Cycle the
power to the H-panel for these settings to take effect.
3.3 HUIO CONFIGURATION
The next act of programming is to tell the H-panel
that a HUIO is to be connected (it’s not plug and
play, if a unit fails we need to know it’s supposed to
be there so we can post a warning if it’s not). Set the
dip switches on the HUIO(s) to give them a unique
Modbus address (see Table 1). If only one unit is to
be connected we suggest leaving both switches in the
“OFF” position to designate the unit as #1. Next go to
the HUIO configuration page and use the check boxes
to select each of the HUIO’s that are to be connected
and apply the change. If the unit is not physically
connected and communicating, a warning will be dis-
played on the front of the H-panel.
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 H Unit Input/Output Manual
If a HUIO is not selected to be connected, then it’s
inputs and outputs will be ignored by the program
EVEN IF IT IS PHYSICALLY CONNECTED.
3.4 SETTING UP THE INPUTS
The new Inputs are numbered 12-27 in groups of
four per HUIO module, for example, inputs 16-19
would always be on unit #2. The inputs appear on
the digital input channel configuration screen just
like any other input. Their status is also displayed
on the input diagnostic screen in Genlink. Inputs can
be given names and can be inverted, delayed, used
to generate an alarm/warning and used to trigger an
event. Refer to the Genlink help screen for this page
if assistance is needed.
A new direct output mapping method allows all of
the new HUIO (only) inputs to be mapped directly to
their own HUIO outputs. Alternatively, any alarm or
warning generated by a HUIO input can be mapped
to the HUIO output. Refer to section "Setting Up
the Outputs" for examples. The new inputs are also
available for use by the ILC programming tool sup-
plied separately by the manufacturer. This allows the
inputs to be logically combined just like a PLC to
drive outputs or to trigger internal functions.
3.5 SETTING UP THE OUTPUTS
The new Outputs are numbered 17-32 in groups
of four per HUIO module, for example, outputs 21-
24 would always be on unit #2. The output status
appears on the digital output diagnostic screen in
Genlink.
The outputs are programmed by mapping them
either to an output function (just like the standard
outputs on the H-panel). Consult the Genlink help
screen for the output function configuration page if
assistance is needed.
Alternatively the new HUIO outputs (ONLY) can be
programmed via a new direct output mapping meth-
od. This allows any HUIO input to be either, directly
mapped to it’s same numbered output, or it allows an
alarm/warning generated by that input to be mapped
to an output. Here are some examples:
HUIO #1, input 1 is directly mapped to HUIO #1
output 1.
• The state of the input is directly reflected by the
output. However the signal can be programmed
to be inverted via the “input active level” setting in
Genlink.
HUIO #2, input 3 is set as a warning and mapped to
HUIO #2, output 3.
• When input 3 becomes active, a warning is gener-
ated. This warning activates output 3.
2
Direct mapping is set up via radio buttons on the dig-
ital input channel configuration screen . These radio
buttons only appear for HUIO inputs and not the
regular inputs. The buttons are labeled as shown:
€ Map Direct
{ Map Alarm/Warning
{ No Mapping
The new outputs are available for use by the ILC pro-
gramming tool supplied separately by the manufac-
turer. This allows the inputs to be logically combined
just like a PLC to drive outputs or to trigger internal
functions.
4.1 INPUT SPECIFICATIONS
Each input is made active via a contact closure to
ground. Two pins per input are provided for this
purpose, one pin is grounded and the other is pulled
up to 5V via a 4700 Ohm resistor. A volt free contact
such as a relay or open collector transistor can be
used to ground the input. The required current car-
rying capacity is in the region of 1mA. See Figure 2
for connection detail to J2.
5.1 OUTPUT SPECIFICATIONS
Each output is made up of a pair of normally open
relay contacts which close when the output is acti-
vated. The relay contacts are form A rated at 30
VDC and up to 5.0A each. NO AC CONNECTIONS
SHOULD BE MADE TO THESE RELAYS. See Figure
2 for connection details to J5. The state of the output
relays can be seen on Led’s 1-4.
6.1 POWER AND COMMUNICATIONS
CONNECTIONS
Power is provided via a two-way Klippon style con-
nector (J1) which would normally be connected to
the generator battery. Requirements are 6-30Vdc at
500 mA.
The RS485 connection is made via a three-way
Klippon style connector (J6). Wiring between units
should be made using a twisted pair shielded cable
such as Belden #9464. The shield should be connect-
ed AT BOTH ENDS as it acts as a common ground
between the isolated ports. The RS485 network starts
at the H-panel and can be daisy chained to various
peripherals such as remote annunciators, remote
relay panels, HTS switches and HUIO’s. There should
be only two terminating resistors in the whole net-
work, one being fixed and in the H-panel. So, when
fitting HUIO’s the terminating jumper should be in
the inactive position (on pins 2 and 3) when:
 H Unit Input/Output Manual

Figure 2 – HUIO Outline

J3 J4
INPUT 1 1 3 RS485+
1

Jmp 1
GROUND FOR INPUT 1 2 2 RS485 SCREEN
3
INPUT 2 1 RS485-
Modbus Address J6
GROUND FOR INPUT 2
On 1 2
INPUT 3
GROUND FOR INPUT 3
8 OUTPUT 4

Led 4
INPUT 4
GROUND FOR INPUT 4 8 OUTPUT 4
J2 OUTPUT 3

Led 3
OUTPUT 3
OUTPUT 2
Led 2 OUTPUT 2
POWER + (12V) 1 OUTPUT 1
POWER - (GND) 2 1 OUTPUT 1
Led 1

J1 J5

NOTE:
1) Power is nominally 12V but can be 6-30 VDC.
2) The RS485 screen should be connected at both ends.
3) JMP 1 is the RS485 terminating resistor and should normally be fitted across Pins 2 and 3. (See manual for details.)
4) J4 is for the connection of a PC based diagnostic monitor.
5) J3 is reserved for the manufacturer’s programming purposes.

A. There is a remote annunciator on the network

(which has a fixed terminator).
7.1 QUICK SETUP
1. Set the Modbus address on the dip switch (e.g.
B. There is an HTS on the network (which has a off, off -for HUIO #1).
fixed terminator). 2. Connect up the RS485 connection.
C. There is a remote relay panel on the network 3. Fit the terminating jumper (jmp1) in the correct
which has a terminating resistor selected. position.
The terminating jumper should be in the active posi- 4. Connect up the power connection.
tion (on pins 1 and 2) when:
5. Connect to the H-panel via Genlink.
A. It is the only peripheral. 6. Set the RS485 port to be a Modbus master and
B. It is at the far end of a bus which ONLY has other choose one of the four required baud rates. If an
HUIO’s on it. old style remote annunciator is fitted the com-
C. It is at the far end of a bus which ONLY has an munications must be set at 4800 baud, no parity
un-terminated remote relay panel on it. and two stop bits. Cycle the power to the H-panel
Finally, don’t worry too much about this termination for these settings to take effect.
business. It is unlikely to have any effect unless you 7. Go to the HUIO configuration page.
are running at maximum bus length and very high 8. Check the “HUIO CONNECTED” box for HUIO #1
speed (such as 57.6k baud). You will not damage the and click apply (or whichever).
equipment if you terminate incorrectly. 9. The unit is now connected and you can allocate
the inputs and outputs as required.
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 H Unit Input/Output Manual

8.1 DIAGNOSTIC MONITOR The custom graphical program displays the screen
in Figure 3.
Provision has been made to fit a diagnostic PCB to the
HUIO. This PCB plugs into socket J4 of the control This interface will allow the HUIO outputs to be over-
board and also to the RS232 communication port of ridden for test purposes.
a PC. The controller should be power cycled AFTER
plugging in the diagnostic PCB OR IT WILL NOT
WORK. The unit can be interrogated either via a the
manufacturer supplied custom graphical program,
or by using “Hyperterminal”. Hyperterminal should
be set for 9600 baud, eight data bits, no parity and
one stop bit. The following commands are available:
M* Examine memory location
T* Enter production test mode
S Display input/output status
V Display internal voltages and hardware version
C Display communication status, current baud rate
and modbus address (dip switches)
* These commands are reserved for the manufacturer use only and
could cause mis-operation of the switch and injury or equipment
damage – DO NOT USE.

Figure 3 – Diagnostic Monitor

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H Unit Input/Output Manual

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 GENERAC® POWER SYSTEMS, INC.
P.O. BOX 8 • WAUKESHA, WI 53187

Part No. 0G5354 Revision A (04/13/07) Printed in U.S.A.