Manual BlueConnect Modules

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"The reproduction, distribution and utilization of this document as well as the communication of its contents to others without express authorization are prohibited. Offenders will be held liable for the payment of damages. All rights reserved in the event of patent, utility model or design registration."

Changes

GO Systemelektronik GmbH retains the right to modify the contents of the manual without prior notice.

Liability Exclusion

GO Systemelektronik GmbH takes no responsibility for correct system operation under all possible operating conditions. It is not possible to guarantee that the software will function completely without error under all possible circumstances. GO Systemelektronik GmbH therefore disclaims all liability for any direct or indirect damage resulting from system operation or the contents of this manual.

Product Observance

Within the scope of our obligation for product observance, GO Systemelektronik GmbH will endeavour to warn third parties about all identified dangers which could arise from the interaction between hardware and software and from the use of other components. Effective product observance is only possible with adequate information from the end user about the planned field of application and the hardware and software used. If the conditions of use change or if the hardware or software is changed, due to the complex relationships between hardware and software, it is no longer possible to describe all possible dangers and their effects on the total system, in particular on our system. This manual does not describe every possible property and combination of the system. For further information, please contact GO Systemelektronik GmbH.

Manufacturer's Declaration

When installing the system, it is necessary to ensure correct electrical connection, protection against moisture and foreign bodies and excessive condensation, and system heating which can arise from both correct and incorrect use. It is the responsibility of the installer to ensure that the correct installation conditions are provided.

GO Systemelektronik GmbH
Faluner Weg 1
24109 Kiel
Germany
Tel.: +49 431 58080-0
Fax: +49 431 58080-11
Website: www.go-sys.de
Email: info@go-sys.de

Creation date: 11.12.2024
Version of this manual: 3.9 en

1 Introduction

This manual describes the BlueConnect Modules of GO Systemelektronik. BlueConnect Modules are available in two basic variants, as Sensor Module and as Input-Output Module (I/O Module).

At the completion of this manual, the following types of design were available:

The type of version can be found on the sticker on the front of the housing or via the article number on the type plate on the right-hand side of the housing.

Note on the article numbers: With the beginning of the year 2022, the BlueConnect Modules have been reassigned the article numbers listed above. The old article numbers are listed in Appendix B - Old Article Numbers.

Note on Text References: References to passages in this document or to passages in other documents are marked in italics. For example, "4.5 The Calibration Window" refers to section 4.5 in this document.

The products of GO Systemelektronik are constantly being developed; therefore, deviations between this manual and the delivered product can result. Please understand that no legal claims can be derived from the contents of this manual.

Caution: The BlueConnect Modules must be installed in such a way that they are not exposed to direct sunlight, rain or snow. Direct sunlight can lead to extreme temperatures, which significantly reduces the service life of electronic components.

2 Description of the BlueConnect Modules

The BlueConnect Modules:

• Transmit the measured values of analog sensors via CAN bus and Modbus.
• Transmit the measured values of Modbus sensors via CAN bus.
• Transmit the measured values of sensors to a PLC.
• Transmit the current values of analog current outputs via CAN bus and Modbus.
• Generate current values from measured values.
• Control an RS232 and RS485 interface via CAN bus.
• Enable the control of relays with freely definable switching conditions.
• Generate measurement values from pulsed signals.

BlueConnect Modules are available in two basic variants, as Sensor Module and as Input-Output Module (I/O Module).

The necessary settings are made on the BlueConnect board and with the enclosed BlueConnect configuration program using a PC (see Section 4: Configuring the BlueConnect Modules with the Program Modbus Tool.exe). The necessary settings for BlueConnect boards without a Modbus connection are made on the board and with the AMS program as part of the BlueBox PC software (and partly also via the BlueBox display).

2.1 System Setup Examples

Connection of analog sensors to a PLC system:

[Diagram showing analog sensors connected to a PLC system]

Connection of analog sensors and Modbus sensors to a BlueBox System:

[Diagram showing analog and Modbus sensors connected to a BlueBox system]

Connection of analog sensors with additional power supply to a BlueBox System:

[Diagram showing analog sensors with additional power supply connected to a BlueBox system]

3 Technical Data and Connections

General Information

Interfaces (depending on version)

Notes on Isolation:

• Bus Module: Modbus and CAN bus are galvanically isolated.
• Current Input and Current Output Module: The two current inputs/outputs are galvanically isolated from the system, but not from each other.
• RS232 and RS485 Module: RS232/RS485 and CAN bus are galvanically isolated.
• Pulse Input Module: The two pulse inputs are galvanically isolated from the system, but not from each other.

Earth the module: This is the only way to ensure trouble-free measuring operation. The earth connection is located on the left side of the housing.

3.1 Opening the Module Housing

Follow these steps to open the module housing:

1. Turn the housing bracket to the right. If necessary, use a suitable tool.
2. Loosen the screws (Torx T20).
3. Open housing cover to the left.

[Diagram showing the steps to open the module housing, indicating screw locations and bracket rotation]

Interior Cover Sticker with pin assignment is shown in Appendix A.

3.2 Cable Connections, Switch Positions and LEDs

The module-specific assignment is shown on the sticker on the inside of the housing cover.

The termination depends on the position of the module in the CAN bus/Modbus. (See also Section 3.3: Notes on termination of older BlueConnect Modules).

Earth the module: This is the only way to ensure trouble-free measuring operation.

Sensor Module (O2, pH, ISE, ORP)

The Modbus interface is optional.

[Diagram showing Sensor Module connections: Earth connection, LED Power, Slide switch S1 (Modbus Termination), Slide switch S2 (CAN bus Termination), and terminal blocks for Sensor, Modbus, and CAN bus. LEDs 1, 2, 3 are indicated.]

Bus Module

[Diagram showing Bus Module connections: Earth connection, LED Power, DIP switches (no function), Slide switch S1 (Modbus Termination), Slide switch S2 (CAN bus Termination), and terminal blocks for Modbus and CAN bus. LEDs 1, 2, 3 are indicated.]

Current Input Module (2x 4–20 mA)

The Modbus interface is optional.

[Diagram showing Current Input Module connections: Earth connection, LED Power, Slide switch S1 (Modbus Termination), Slide switch S2 (CAN bus Termination), and terminal blocks for Modbus, CAN bus, Current in 1, and Current in 2. LEDs 1, 2, 3 are indicated.]

Current Output Module (2x 4–20 mA)

The Modbus interface is optional.

[Diagram showing Current Output Module connections: Earth connection, LED Power, Slide switch S1 (Modbus Termination), Slide switch S2 (CAN bus Termination), and terminal blocks for Current out 1, Current out 2, Modbus, and CAN bus. LEDs 1, 2, 3 are indicated.]

RS232 Module

[Diagram showing RS232 Module connections: Earth connection, LED Power, DIP switches for COM Port setting, and terminal blocks for RS232 and CAN bus. LEDs 1, 2, 3 are indicated. Text indicates factory setting: COM2 (COM Port 2).]

RS485 Module

[Diagram showing RS485 Module connections: Earth connection, LED Power, DIP switches for COM Port setting, Slide switch S1 (Modbus Termination), Slide switch S2 (CAN bus Termination), and terminal blocks for RS485 and CAN bus. LEDs 1, 2, 3 are indicated. Text indicates factory setting: COM2 (COM Port 2).]

Relay Module

The Modbus interface is optional. Relay outputs Umax = 48 V, Imax = 2 A per Relay.

[Diagram showing Relay Module connections: Earth connection, LED Power, Slide switch S1 (Modbus Termination), Slide switch S2 (CAN bus Termination), and terminal blocks for Relay 1 and Relay 2, Modbus, and CAN bus. LEDs 1, 2, 3 are indicated.]

Pulse Input Module

The Modbus interface is optional.

[Diagram showing Pulse Input Module connections: Earth connection, LED Power, Slide switch S1 (Modbus Termination), Slide switch S2 (CAN bus Termination), and terminal blocks for Pulse 1, Pulse 2, Modbus, and CAN bus. LEDs 1, 2, 3 are indicated. Jumper assignment is shown, with factory setting NPN.]

LED-Functions

• LED Power: Supply voltage is present.
• LED 1: Flashing – frequency 0.5 Hz, main processor is in operation.
• LED 2: Data transmission Modbus/RS232/RS485.
• LED 3: Data transmission CAN bus.

Functionality of a cable clamp: [Description of cable clamp functionality with two diagrams showing insertion and securing of a cable]

3.3 Notes on Termination of Older BlueConnect Modules

• Older modules have no slide switches on the board.
• With older BlueConnect Sensor and Bus Modules, the termination of CAN bus and Modbus is done via the configuration program Modbus Tool.exe (see Section 4.13: Configuring Older Bus Modules).
• Older modules are not terminated at the factory.

If there is no possibility to terminate the CAN bus via the configuration program:

CAN bus termination by means of a resistor of approx. 120 Ω on the open terminals for CAN-H and CAN-L on slot X4. Modbus termination by means of a resistor of approx. 120 Ω on the open terminals for TX/RX+ and TX/RX- on slot X3.

[Diagram illustrating CAN bus termination with a resistor on terminals X4]

3.3 PIN Assignment

If the two terminals of slot X9 are not occupied, the open input must be terminated with a resistance of approx. 1.2 kΩ (except for O2/Temp, where it is approx. 27 kΩ).

Sensor Module PIN Assignments:

• pH-Glass Temp.: X8 (+), X9 (Temp.)
• ISE Temp.: X8 (+), X9 (Temp.)
• ORP Temp.: X8 (+), X9 (Temp.)

Modbus and CAN Bus Connections:

• pH-Glass/Temp.: X3 (Modbus), X4 (CAN bus)
• O2/Temp.: X3 (Modbus), X4 (CAN bus)

Module Specific Connections:

• Modbus BlueTrace (Oil): X3 (Modbus)
• Modbus BlueTrace (Crude oil): X3 (Modbus)
• Modbus BlueTrace (Turb.): X3 (Modbus)
• Modbus BlueEC (Cond.): X3 (Modbus)
• Modbus O2: X3 (Modbus)
• Modbus Turb. flow through: X3 (Modbus)

Note: The old BlueEC cable had the colours BK BN WH BU. Refer to Interior Cover Sticker and Data Sheet BlueEC.

Input/Output Connections:

• Current input: X8/X9
• Current output: X6/X7
• RS232: X3
• RS485: X3
• Relay: X6 (Relay 1), X6 (Relay 2)
• Pulse: X6 (Pulse 1), X7 (Pulse 2)

3.4 PIN Assignment CAN Bus at the BlueBox

BlueBox T4 Panel socket (M12, female):

• 1: CAN-H
• 2: CAN-L
• 3: +24 VDC
• 4: GND 24 V

Mainboard of the BlueBox R1 and BlueBox Panel:

Slot X07 (BlueBox R1) or Slot X4 (BlueBox Panel) (See Manual BlueBox R1 and Panel).

4 Configuring the BlueConnect Modules with the Program Modbus Tool.exe

This chapter describes the operation of the BlueConnect configuration program Modbus Tool.exe of GO Systemelektronik (article number 420 6500, software version 1.10). It allows users to read sensor information, assign a Modbus address, calibrate sensors, and display measurement values, depending on the module and sensor type.

On older Sensor and Bus Modules without slide switches, the Modbus (RS485) and the CAN bus can be terminated.

• The configuration of the Bus Module is done automatically. Older bus modules may require specific configuration (see Section 4.13: Configuring Older Bus Modules).
• The configuration of the Bus Module Turbidity flow through is done at the BlueBox and is not described here.
• The configuration of the Relay and Sensor Modules can also be done via the BlueBox menu and the BlueBox PC Software.
• The configuration of the Current Modules can also be done via the BlueBox menu and the BlueBox PC Software.
• The configuration of the RS232 Modules is done via DIP switches (see Section 3.2: Cable Connections, Switch Positions and LEDs for RS232 Module and RS485 Module).

Decimal separator is the comma.

The program is executable under Windows 7 and newer. Installation is not necessary; the program starts when Modbus Tool.exe is called up. The program automatically detects connected modules and their sensors. Modbus Tool.exe is included with every BlueConnect Module.

In the program windows, internal module designations are used:

• pH + Temp. = BlueConnect pH
• ISE + Temp. = BlueConnect ISE
• ORP + Temp. = BlueConnect Redox
• Oxygen = BlueConnect O2
• Conductivity = Conductivity
• Oil in Water = BlueTrace Oil in Water
• Turbidity = BlueTrace Turbidity
• Current Input Module = BlueConnect Current In
• Current Output Module = BlueConnect Current Out
• Relay Module = BlueConnect Relay
• Pulse Input Module = BlueConnect Pulse Input

4.1 Preparation

To enable your PC to communicate with a Modbus sensor, you need a converter from RS485 to USB and driver software. An example is the Modbus USB converter from GO Systemelektronik (Article No. 486 S810) with driver software available at https://ftdichip.com/drivers/d2xx-drivers (look for "D2XX Drivers"). The driver software creates a virtual COM Port in the Windows system (e.g., "USB Serial Port (COMn)").

[Diagram showing a converter connected to a BlueConnect Module slot X3 via slot X1, with an earth connection indicated on the converter board.]

In case of communication problems:

• Check the earthing of the converter.
• Install the latest driver software.

4.2 Title Bar and Menu Bar

[Screenshot of the Modbus Tool V1.07 window showing the title bar and menu bar with numbered elements indicating minimize, exit, and language selection.]

• 1: Minimizes the window.
• 2: Closes the program.
• 3: Selects the program language (English/Deutsch).

4.3 The Start Window (Modbus Connection)

The Modbus connection window opens. Click the <Start> button. The Select Port window opens, allowing you to choose the correct COM Port for communication with the converter. The COM Port is displayed in the Windows Device Manager (e.g., USB Serial Port (COMn)). The program detects the connected BlueConnect Module. You can change the COM Port via the <Change COM Port> option.

[Screenshot of the Modbus Tool Start Window showing connection options and the Select Port window.]

Note: The default Modbus Slave ID of a BlueConnect Sensor Module is 1 and typically does not need to be changed.

4.4 The Info Window

After the program detects the connected module (e.g., Redox/ORP), the module info window opens, displaying device information such as Firmware Version, Serial Number, Modbus Slave ID, Baudrate, and Production Date.

[Screenshot of the Modbus Tool Info Window for a BlueConnect Redox module.]

4.5 The Calibration Window

The Calibration Window allows comparison of measured sensor raw values with allocated reference values from calibration liquids. These value pairs form points on a coordinate system, and a polynomial curve (1st to 5th order) is fitted to these points to create the calibration polynomial.

A raw sensor value is the uncalibrated sensor measurement value or the uncalibrated current input value.

[Screenshot of the Modbus Tool Calibration Window showing the calibration table and coefficients.]

4.5.1 The Calibration Table

There are two ways to enter raw values:

• Manual input: Allows manual entry of raw values and reference values. You can set up to 10 value pairs.
• Measurement value transfer: Uses current measured raw values for actual calibration.

Note: Decimal separator is the comma; dots are not accepted.

After opening the calibration view, the table has one row. Enter the first raw value and the corresponding reference value. To create a new row, press ENTER after the last entry. To delete a row, clear all entries and click elsewhere.

Order: Select the order/degree of the calibration polynomial (1 to 5) for the best fit. The graph of the calibration polynomial is displayed.

Apply Coefficients: Writes the calculated coefficient values into the sensor.

4.6 The Measurement Value Window

This window displays the current measurement values, which are updated every second. The <read> button starts and stops the measurement value display.

[Screenshot of the Modbus Tool Measurement Value Window showing real-time readings for Redox and Temperature.]

4.7 The Measurement Value Recording Window

This window allows for data logging. You can select the recording interval and save the data in CSV format. The <read> button starts and stops the measurement value display. The <save (csv format)> button opens a window to specify the storage path for the CSV file. Once the file is created, data recording begins. The button changes to indicate "Data Logger running". Click <Stop> to halt data recording.

[Screenshot of the Modbus Tool Measurement Value Recording Window showing Sensor live data, Data Logger settings, and real-time charts.]

4.8 Configuring the Sensor Modules

4.8.1 The Parameter Window

This window allows configuration of sensor-specific parameters, including RS485/CAN Termination settings (for older modules), O2 unit selection (mg/l or % saturation), and calibration coefficients for O2 and temperature. Changes are saved by clicking "write changes". Settings not yet saved are marked in red.

[Screenshot of the Modbus Tool Parameter Window for an O2 sensor module.]

• RS485 / CAN Termination: Switches the termination of the Modbus (RS485) and CAN bus on/off. Applies to older modules; newer modules with slide switches ignore this setting.
• O2: Visible only for O2 Sensor Modules. Allows selection of measurement unit (mg/l or % Saturation), which determines calibration type and value display.
• Coefficients O2: Displays calibration coefficients obtained from the Calibration function.
• Coefficients Temperature: Displays factory calibration coefficients for the temperature sensor. Offset can be adjusted via Coefficient A0.

Note: Decimal separator is the comma; if a dot is entered, an error message appears.

4.8.2 The Calibration Window O2

The O2 sensor calibration is a two-point calibration. One point is the zero point, and the other is determined by saturation in air (100%) or a pair of measured values from the sensor and a reference device in the same medium.

[Screenshot of the Modbus Tool Calibration Window O2, showing fields for Oxygen, Temperature, Reference values, and calibration buttons.]

Reference calibration (mg/l)

Prerequisite: Setting O2 Unit to mg/l (see Section 4.8.1).

1. Click <Start>.
2. Immerse the oxygen sensor in the measurement medium and wait for stable values.
3. Enter the oxygen content of the measurement medium according to the reference measuring device.
4. Click <mg/l Calibration>.
5. Calibration is complete.

Saturation calibration (100%)

Prerequisite: Setting O2 Unit to % (see Section 4.8.1).

1. Click <Start>.
2. Hold the oxygen sensor in the air. Wait at least 10 minutes for stable values.
3. Click <100% Calibration>.
4. Calibration is complete.

Note: Decimal separator is the comma; if a dot is entered, an error message appears.

Detailed notes on temperature adjustment for saturation calibration are provided.

4.9 Configuring the Current Input Module

The Current Input Module features two 4–20 mA current inputs. Calibration is detailed in Sections 4.5 and 4.5.1. The parameter window displays calibration coefficients for both current inputs. Use "write changes" to save settings.

[Screenshot of the Modbus Tool Parameter Window for the Current Input Module.]

Note: Decimal separator is the comma; if a dot is entered, an error message appears.

4.10 Configuring the Current Output Module

The Current Output Module provides two 4–20 mA current outputs. Calibration is covered in Sections 4.5 and 4.5.1. The parameter window shows calibration coefficients for current outputs. The "set" button allows testing by outputting a specific current value. "write changes" saves the settings.

[Screenshot of the Modbus Tool Parameter Window for the Current Output Module, showing coefficients and output setting fields.]

Note: Decimal separator is the comma; if a dot is entered, an error message appears.

4.11 Configuring the Relay Module

The Relay Module has two relays. The parameter window allows adjustment of switching values via coefficients (y = A0 + A1x). "write changes" saves the settings. The "set" button on Relay 1 and Relay 2 controls the relays, typically with input values of 0 or 1.

[Screenshot of the Modbus Tool Parameter Window for the Relay Module, showing coefficients and relay control fields.]

Note: Decimal separator is the comma; if a dot is entered, an error message appears.

4.12 Configuring the Pulse Input Module

The Pulse Input Module has two pulse inputs. The parameter window allows configuration of Sensor Type (Static, Frequency edge trigger, Frequency debounced, Watchdog), Debounce Timeout, Interval, and Pulse Coefficients. "write changes" saves the settings.

[Screenshot of the Modbus Tool Parameter Window for the Pulse Input Module.]

• Sensor Type Input: Selects input type (Static, Frequency, Watchdog).
• Debounce Timeout: Sets timeout after triggering in ms.
• Interval Input: Sets the measurement interval in seconds.
• Coefficients Pulse: Used to adapt to the pulse generator and convert measured values.

Note: Decimal separator is the comma; if a dot is entered, an error message appears.

4.13 Configuring Older Bus Modules

Older BlueConnect Bus Modules lack slide switches for termination; this is configured via the Parameter Window in Modbus Tool. RS485 and CAN bus termination can be selected on/off. For older modules, Modbus sensors are not auto-detected and require manual sensor identifier selection.

[Screenshot of the Modbus Tool Parameter Window for older Bus Modules, showing termination and sensor selection options.]

5 Modbus Addresses Overview of the Sensor Modules

This section details the Modbus addresses for various BlueConnect sensor modules.

BlueConnect O2 486 CS00-4

Note on 32 bit Float data: The receiving sequence of values (Hex) is: 0x [Byte2] [Byte1] [Byte4] [Byte3].

BlueConnect pH 486 CS00-5

Note on 32 bit Float data: The receiving sequence of values (Hex) is: 0x [Byte2] [Byte1] [Byte4] [Byte3].

BlueConnect ISE 486 CS00-7

Note on 32 bit Float data: The receiving sequence of values (Hex) is: 0x [Byte2] [Byte1] [Byte4] [Byte3].

BlueConnect Redox 486 CS00-9

Note on 32 bit Float data: The receiving sequence of values (Hex) is: 0x [Byte2] [Byte1] [Byte4] [Byte3].

6 Modbus Addresses Overview Pulse Input 486 CI00-PI2

Note on 32 bit Float data: The receiving sequence of values (Hex) is: 0x [Byte2] [Byte1] [Byte4] [Byte3].

7 Supplement BlueConnect Plus Board

The BlueConnect Plus board can be equipped with up to four BlueConnect boards and installed internally in a BlueBox or a sensor module. Connection is via the CAN bus. Individual BlueConnect boards appear as DAM (Data Acquisition Module) in the BlueBox System.

Settings for BlueConnect boards without Modbus connection are made using the AMS program (part of BlueBox PC Software) or via the BlueBox display control.

A BlueConnect board is mounted with 4 hex socket screws (3 mm). Board slots 1 to 4 can be equipped as desired. The example shows slot 1 with a bus board and slot 2 with an RS232 board.

Connections:

• The connection to the BlueBox System is made via the CAN bus connection X1.
• An additional voltage supply can be connected via connection X2.
• The LED lights up when the BlueConnect Plus board is supplied with voltage.
• The CAN bus connection of the BlueConnect boards is made via the pin headers at slots 1 to 4.
• The CAN bus termination of the BlueConnect Plus board is done with the slide switch to the right of the CAN bus connection of the last BlueConnect board in the sequence (e.g., on slot 2).

Terminal assignment:

Clamp socket X1 (CAN bus): 1: CAN-H, 2: CAN-L, 3: +24 VDC, 4: GND 24 V

Clamp socket X2 (Voltage supply): 1: Power, 2: GND

Pin header: 1: CAN-H, 2: CAN-L, 3: Power, 4: GND

Appendix A – Interior Cover Stickers

This appendix provides diagrams illustrating the interior cover stickers for various BlueConnect modules, showing terminal assignments and switch configurations.

Sensor Modules:

• O2/Temp. (486 CS00-4): Shows connections for Sensor, Modbus, CAN bus, termination switches S1/S2, and LEDs. Includes notes on terminating open inputs with resistors.
• pH/Temp. (486 CS00-5): Similar to O2/Temp.
• ISE/Temp. (486 CS00-7): Similar to O2/Temp.
• ORP Temp. (486 CS00-9): Similar to O2/Temp.

Bus Modules:

• Modbus (486 CS00-MOD): Shows connections for Modbus, CAN bus, termination switches S1/S2, and LEDs.
• Turbidity flow through (486 CS00-FNU): Similar to Modbus Bus Module.

Input/Output Modules:

• Current output (486 CI00-AI2, 486 CI00-AO2): Shows connections for Current out 1, Current out 2, Modbus, CAN bus, termination switches S1/S2, and LEDs.
• RS232 5 V (486 C100-S05), RS232 12 V (486 C100-S12): Show DIP switch configurations for COM port selection, RS232 and CAN bus connections, termination switches S1/S2, and LEDs.
• RS485 5 V (486 C100-M05), RS485 12 V (486 C100-M12), RS485 24 V (486 C100-M24): Show DIP switch configurations, RS485 and CAN bus connections, termination switches S1/S2, and LEDs.
• Relay (486 C100-REL): Shows connections for Relay 1, Relay 2, Modbus, CAN bus, termination switches S1/S2, and LEDs. Includes notes on voltage/current limits.
• Pulse Input (486 C100-P12): Shows connections for Pulse 1, Pulse 2, Modbus, CAN bus, termination switches S1/S2, and LEDs. Includes jumper assignment details.

Appendix B – Old Article Numbers

This appendix lists old article numbers for various BlueConnect modules: