1. Product Overview

Product Name: EX9019
Model: EX9019 / EX9019-M
Series: EX-9000 Series Analog Input Modules
Article Number: EX9019
Manufacturer: ICP DAS (Industrial Control Products Data Acquisition Systems)

The EX9019 is a high-precision, isolated 8-channel analog input module designed for thermocouple, voltage, and current measurement applications. It belongs to the EX-9000 series of distributed I/O modules and communicates via a two-wire RS-485 interface. The module supports both ASCII and Modbus RTU protocols (the “-M” variant includes Modbus RTU support). It is engineered for industrial environments requiring accurate temperature and analog signal acquisition with galvanic isolation, open-loop detection, and individual channel configuration.

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2. Key Features

- 8 Differential Analog Input Channels: Each channel can be configured independently for thermocouple, voltage, or current input.
- High Resolution: 16-bit A/D conversion ensures precise measurement and low noise.
- Wide Input Range: Supports multiple voltage ranges (±15 mV to ±2.5 V), current range (±20 mA with external resistor), and thermocouple types J, K, T, E, R, S, B, and N.
- Individual Channel Configuration: Each input channel can be set to a different input type or range (EX9019/EX9019-M only).
- Open Loop (Burnout) Detection: Detects thermocouple disconnection or sensor failure.
- Galvanic Isolation: Input and output circuits are isolated to prevent ground loops and electrical interference.
- RS-485 Communication: Two-wire serial interface supporting baud rates from 1200 to 115200 bps.
- Modbus RTU Protocol (EX9019-M): Compatible with standard Modbus RTU master devices such as PLCs, HMIs, and SCADA systems.
- Cold Junction Compensation (CJC): Built-in temperature compensation for accurate thermocouple readings.
- Dual Watchdog System: Hardware and host watchdogs ensure reliable operation and automatic recovery from communication or system faults.
- Wide Power Supply Range: Operates from +10 VDC to +30 VDC.
- Compact and Rugged Design: Suitable for DIN-rail or panel mounting in industrial environments.
- Software Configurable: Supports configuration via ASCII commands or EX-9000 utility software.
- Firmware and Module Identification: Built-in commands to read firmware version and module name.

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3. Technical Specifications

| Parameter | Specification |
|----------------|------------------|
| Interface | RS-485, 2-wire |
| Communication Speed | 1200, 2400, 4800, 9600, 19200, 38400, 57600, 115200 bps |
| Analog Input Type | Differential |
| Number of Channels | 8 |
| Resolution | 16 bits |
| Sampling Rate | 10 samples per second (10 Hz) |
| Bandwidth | 15.7 Hz |
| Accuracy | ±0.1% of full scale |
| Zero Drift | 0.5 μV/°C |
| Span Drift | 25 ppm/°C |
| Input Impedance | 20 MΩ |
| Common Mode Rejection (CMR) | 150 dB @ 50/60 Hz |
| Normal Mode Rejection (NMR) | 100 dB @ 50/60 Hz |
| Power Supply | +10 VDC to +30 VDC |
| Power Consumption | Typically < 2 W |
| Isolation | Galvanic isolation between input and output |
| Operating Temperature | -25 °C to +75 °C (typical for EX-9000 series) |
| Storage Temperature | -40 °C to +85 °C |
| Humidity | 10–90% RH, non-condensing |
| Dimensions | Approx. 72 mm (W) × 118 mm (H) × 35 mm (D) |
| Weight | Approx. 150 g |
| Mounting | DIN-rail or wall mount |

Input Ranges:
- Voltage: ±15 mV, ±50 mV, ±100 mV, ±500 mV, ±1 V, ±2.5 V
- Current: ±20 mA (requires external 125 Ω precision resistor, 0.1%)
- Thermocouple Types: J (-210 to +760 °C), K (-270 to +1372 °C), T (-270 to +400 °C), E (-270 to +1000 °C), R (0 to +1768 °C), S (0 to +1768 °C), B (0 to +1820 °C), N (-270 to +1300 °C)

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4. Functionality

The EX9019 functions as a multi-input analog acquisition module capable of reading temperature and analog signals from various sensors. Each of its eight channels can be configured independently to measure thermocouple, voltage, or current signals. The module converts analog signals into 16-bit digital data and transmits them over an RS-485 network to a host controller or SCADA system.

Use Cases and Applications:
- Industrial process monitoring and control
- Temperature measurement in furnaces, kilns, and HVAC systems
- Data acquisition for laboratory and research environments
- Integration with PLCs, HMIs, and SCADA systems via Modbus RTU
- Multi-sensor monitoring in distributed control systems
- Energy management and environmental monitoring applications

Compatibility:
- Compatible with Modbus RTU master devices (EX9019-M)
- Works with ICP DAS software utilities and third-party SCADA systems
- Supports ASCII command mode for direct serial communication

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5. Components & Accessories

Included Items:
- EX9019 module
- User manual and configuration guide
- Mounting hardware (DIN-rail clip)

Optional Accessories:
- External 125 Ω precision resistor (for current measurement)
- RS-485 communication cable
- Power supply (10–30 VDC)
- EX-9000 configuration utility software

Connectors:
- Screw terminal blocks for analog input channels
- RS-485 communication terminals (D+, D–)
- Power input terminals (+Vs, GND)
- INIT* terminal or switch for configuration reset

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6. Installation & Setup

Requirements:
- DC power supply between +10 V and +30 V
- RS-485 network connection (2-wire twisted pair)
- Proper grounding and shielding for noise immunity

Mounting Options:
- DIN-rail mounting (standard)
- Panel or wall mounting (optional)

Configuration:
- Default module address: 01
- Default baud rate: 9600 bps
- Default filter: 60 Hz rejection
- Default data format: Engineering unit
- Checksum: Disabled by default

Setup Procedure:
1. Connect power and RS-485 lines.
2. Use the INIT* switch or terminal to enter initialization mode if configuration reset is required.
3. Configure module address, baud rate, and input types using ASCII commands or EX-9000 utility.
4. For Modbus RTU operation, set protocol mode and verify communication parameters.
5. Connect sensors to the appropriate input terminals.
6. Verify operation using test commands or Modbus registers.

Calibration:
- Zero and span calibration can be performed via ASCII commands.
- Calibration requires applying known reference signals to the input channels.
- Warm-up time of 30 minutes is recommended before calibration or measurement.

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7. Performance & Capabilities

- Sampling Rate: 10 samples per second across all channels.
- Bandwidth: 15.7 Hz, suitable for slow to moderate signal variations.
- Accuracy: ±0.1% of full scale ensures reliable measurement.
- Noise Immunity: High CMR (150 dB) and NMR (100 dB) provide excellent rejection of electrical interference.
- Temperature Stability: Low zero drift (0.5 μV/°C) and span drift (25 ppm/°C).
- Isolation: Protects against ground loops and voltage surges.
- Reliability: Dual watchdog system (module and host) ensures continuous operation even under communication loss or system faults.
- Limitations: Sampling rate limited to 10 Hz; not suitable for high-speed dynamic signal acquisition.

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8. Standards & Compliance

- Communication Protocols: ASCII and Modbus RTU (EIA RS-485 standard)
- Electrical Isolation: Meets industrial isolation standards for analog and communication circuits
- EMC Compliance: Designed for industrial electromagnetic compatibility (EN 61000 series)
- Safety: Conforms to low-voltage DC operation standards
- Industry Standards: Compatible with Modbus RTU protocol specifications as defined by Modicon and Modbus.org

Certifications (typical for EX-9000 series):
- CE Mark (EMC and Safety compliance)
- RoHS Compliant (Restriction of Hazardous Substances)

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9. Additional Information

Warranty:
Typically 1-year limited warranty covering manufacturing defects and hardware failures under normal operating conditions.

Technical Support:
ICP DAS provides technical documentation, configuration utilities, and firmware updates. Support is available through online resources, manuals, and customer service channels.

Maintenance:
- Periodic inspection of wiring and terminal connections recommended.
- Ensure proper ventilation and avoid exposure to excessive vibration or moisture.
- Calibration may be performed periodically to maintain accuracy.

Firmware & Updates:
- Firmware version can be read using command `$AAF`.
- Module name and configuration can be verified using `$AAM`.
- Firmware updates may be available from ICP DAS for performance improvements or protocol enhancements.

Operational Notes:
- Warm-up for 30 minutes before measurement for optimal accuracy.
- Use precision resistors for current measurement.
- Ensure proper grounding and shielding for thermocouple inputs.
- Avoid calibrating unless fully familiar with the procedure.

Modbus Mapping Summary (EX9019-M):
- Input Registers (30001–30008): Analog input values
- Cold Junction Temperature (30129): Temperature in 0.1 °C units
- Input Type Codes (30201–30208): Channel configuration
- Channel Enable (30221): Channel status bits
- Burnout Status (30281): Thermocouple open-line detection
- Channel Offset (30291–30298): Calibration offsets
- Holding Registers (40001–40008): Writable analog input values and configuration parameters

Supported Modbus Functions:
- Function 0x03: Read holding registers
- Function 0x04: Read input registers
- Function 0x05: Write single coil (WDT control)
- Function 0x06: Write single register (WDT timeout)
- Function 0x46: Sub-function for module name and address configuration

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Summary

The EX9019 is a versatile, high-accuracy 8-channel analog input module designed for industrial temperature and analog signal measurement. With 16-bit resolution, galvanic isolation, and support for multiple thermocouple types and voltage/current ranges, it provides a flexible solution for distributed data acquisition systems. The module’s RS-485 interface and Modbus RTU compatibility (in the EX9019-M variant) make it easy to integrate into existing automation networks. Features such as open-loop detection, cold junction compensation, and dual watchdogs enhance reliability and safety in demanding environments. Its robust design, wide power range, and configurable channels make it ideal for process control, monitoring, and industrial automation applications.