Comprehensive Product Summary – ExpertDAQ EX9060D Relay Module

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### 1. Product Overview

Product Name: ExpertDAQ 4DI/4Relay Output Module
Model: EX9060D
Series: EX9000 Series Distributed I/O Modules
Article Number: EX9060D
Manufacturer: ExpertDAQ (Expert Data Acquisition Systems)

The ExpertDAQ EX9060D is a compact, industrial-grade RS-485 relay and digital input module designed for distributed control and monitoring applications. It provides four isolated digital input channels and four relay output channels, supporting both Form A and Form C relay configurations. The module communicates via the RS-485 interface and supports baud rates up to 115.2 kbps. It is available in two variants: the EX9060D (standard ASCII command mode) and the EX9060D-M (Modbus RTU protocol support). The device is engineered for robust operation in harsh environments, offering high isolation, wide operating temperature range, and integrated hardware and software watchdogs for system reliability.

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### 2. Key Features

- 4 Relay Outputs: Two Form A (normally open) and two Form C (changeover) relay outputs for flexible control of AC and DC loads.
- 4 Isolated Digital Inputs: Optically isolated channels with 3750 Vrms isolation voltage for reliable signal acquisition.
- RS-485 Communication: Two-wire serial interface supporting up to 256 modules on a single network segment.
- Protocol Options: ASCII command set (EX9060D) or Modbus RTU (EX9060D-M) for seamless integration with PLCs, SCADA, and industrial control systems.
- High-Speed Switching: Relay operate time of 3 ms and release time of 2 ms for fast response.
- LED Indicators: Individual channel LEDs for input/output status monitoring.
- Wide Power Supply Range: Operates from +10 VDC to +30 VDC, suitable for industrial power systems.
- Dual Watchdog System: Hardware and host watchdogs ensure continuous operation and fail-safe output states.
- Extended Temperature Range: Operates from -25°C to +75°C, storage down to -30°C.
- Long Relay Life: Minimum mechanical life of 5 × 10⁵ operations.
- Compact and Rugged Design: Built for DIN-rail or panel mounting in industrial environments.
- Manual or Software Configuration: Adjustable address, baud rate, and data format via commands or configuration software.

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### 3. Technical Specifications

| Parameter | Specification |
|----------------|-------------------|
| Interface | RS-485, 2-wire |
| Communication Speed | 1200, 2400, 4800, 9600, 19.2K, 38.4K, 57.6K, 115.2K bps |
| Output Channels | 4 relay outputs (RL1–RL4) |
| Relay Type | RL1, RL2: Form A (SPST-NO); RL3, RL4: Form C (SPDT) |
| Contact Rating (AC) | 125 VAC @ 0.6 A |
| Contact Rating (DC) | 30 VDC @ 2 A |
| Surge Strength | 500 V |
| Operate Time | 3 ms (typical) |
| Release Time | 2 ms (typical) |
| Insulation Resistance | 1000 MΩ @ 500 VDC |
| Relay Life Expectancy | ≥ 5 × 10⁵ operations |
| Input Channels | 4 isolated digital inputs |
| Input Impedance | 3 kΩ |
| Logic Level 0 | ≤ +1 VDC |
| Logic Level 1 | +4 VDC to +30 VDC |
| Isolation Voltage | 3750 Vrms (input-to-output and channel-to-system) |
| Power Supply | +10 VDC to +30 VDC |
| Power Consumption | 1.9 W (EX9060D), 1.8 W (EX9060D-M) |
| Operating Temperature | -25°C to +75°C |
| Storage Temperature | -30°C to +75°C |
| LED Indicators | 8 LEDs (4 for inputs, 4 for outputs) |
| Mounting | DIN-rail or panel mount |
| Communication Protocols | ASCII (EX9060D), Modbus RTU (EX9060D-M) |
| Isolation Type | Optical isolation for inputs, galvanic isolation for communication |
| Housing | Industrial-grade plastic enclosure |

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### 4. Functionality

The EX9060D functions as a distributed digital I/O module for remote control and monitoring over an RS-485 network. It provides four isolated digital inputs for sensing external signals such as switches, sensors, or logic-level devices, and four relay outputs for controlling actuators, alarms, or other electrical loads.

Operation Principle:
- Inputs: Each input channel detects voltage levels between +4 V and +30 V as logic high, and below +1 V as logic low. The inputs are optically isolated to prevent ground loops and electrical interference.
- Outputs: The relay outputs can switch AC or DC loads. Form A relays provide normally open contacts, while Form C relays offer both normally open and normally closed contacts for flexible wiring.
- Communication: The module communicates via RS-485 using ASCII or Modbus RTU commands. Each module has a unique address (default 01) and can be configured for baud rate and data format.
- Watchdog Function: The dual watchdog system ensures that if communication is lost or the host fails, outputs revert to predefined safe states.
- EEPROM Configuration: Module settings such as address, baud rate, and safe/power-on values are stored in non-volatile memory.

Typical Applications:
- Industrial automation and process control
- Building management systems (BMS)
- Remote monitoring and control of machinery
- Energy management and environmental monitoring
- SCADA and PLC-based distributed I/O systems

Compatibility:
- Compatible with Modbus RTU master devices (EX9060D-M)
- Integrates with ExpertDAQ configuration software and third-party SCADA systems
- Supports up to 256 modules on a single RS-485 bus (up to 1200 m without repeater)

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### 5. Components & Accessories

Included Components:
- EX9060D module
- Terminal block connectors for power, RS-485, and I/O channels
- User manual and configuration guide

Optional Accessories:
- RS-485 to USB converter for PC configuration
- RS-485 repeaters for extended network distance
- DIN-rail mounting clips
- Power supply (10–30 VDC regulated)

Connectors:
- Power Input: 2-pin terminal block (+V, GND)
- RS-485 Interface: 2-pin terminal block (DATA+, DATA–)
- Digital Inputs: 4-channel terminal block (DI1–DI4, common source)
- Relay Outputs: 4-channel terminal block (RL1–RL4, individual commons)

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### 6. Installation & Setup

Requirements:
- Power supply: +10 to +30 VDC
- RS-485 network connection with proper termination resistors
- Host controller or PC with RS-485/USB interface

Mounting Options:
- DIN-rail mounting for control cabinets
- Panel mounting using screws or brackets

Configuration Steps:
1. Power Off the Module before wiring.
2. Connect Power and RS-485 Lines according to the wiring diagram.
3. Set Module Address and Baud Rate using ASCII commands or configuration software.
4. Use INIT* Mode for resetting configuration or changing baud rate/checksum.
- Activate by connecting INIT* pin to GND or sliding the INIT switch to “Init” position.
5. Verify Communication using test commands (e.g., `$AA6` to read I/O status).
6. Set Safe and Power-On Values to define output states after reset or communication loss.

Default Settings:
- Module Address: 01
- Baud Rate: 9600 bps
- DIO Type: 40
- Protocol: ASCII (EX9060D) / Modbus RTU (EX9060D-M)

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### 7. Performance & Capabilities

- Switching Speed: 3 ms ON, 2 ms OFF
- Relay Capacity: 0.6 A @ 125 VAC or 2 A @ 30 VDC
- Input Response: TTL/CMOS compatible, optically isolated
- Network Capacity: Up to 256 modules per RS-485 segment
- Cable Length: Up to 1200 m without repeater
- Reliability: Dual watchdogs ensure continuous operation
- Data Integrity: EEPROM stores configuration and safe values
- Power Efficiency: Low power consumption (1.8–1.9 W)
- Environmental Robustness: Operates reliably in industrial temperature ranges and noisy environments

Limitations:
- Relay outputs are mechanical; not suitable for high-frequency switching applications.
- Maximum load current limited to 2 A DC or 0.6 A AC per channel.
- Requires proper RS-485 termination for long-distance communication.

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### 8. Standards & Compliance

- Communication Standards: RS-485, Modbus RTU (EX9060D-M)
- Electrical Isolation: 3750 Vrms optical isolation
- Safety and EMC: Designed for industrial environments with surge protection up to 500 V
- Protocol Compliance: Fully compliant with Modbus RTU function codes (0x01, 0x02, 0x03, 0x05, 0x0F, etc.)
- Quality Assurance: Manufactured under ISO-certified processes
- Environmental Compliance: RoHS-compliant materials and lead-free soldering

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### 9. Additional Information

Warranty:
Standard manufacturer warranty covers defects in materials and workmanship for a specified period (typically 1–2 years depending on region).

Technical Support:
ExpertDAQ provides technical documentation, configuration software, and online support resources. Firmware updates and configuration utilities are available through the manufacturer’s website.

Maintenance:
- Periodic inspection of terminal connections and relay contacts recommended.
- Avoid exposure to excessive humidity or corrosive environments.
- Firmware can be updated via RS-485 interface if required.

Firmware & Software Updates:
- Firmware version can be read using `$AAF` command (e.g., version D03.11).
- Configuration and monitoring supported through ExpertDAQ software or Modbus-compatible SCADA systems.

Reliability Features:
- Dual Watchdog System: Hardware watchdog resets the module in case of internal fault; host watchdog monitors communication timeout and sets outputs to safe values.
- EEPROM Storage: Retains configuration, safe values, and power-on states even after power loss.
- LED Diagnostics: Visual indication of input/output states and communication activity.

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### Summary

The ExpertDAQ EX9060D is a versatile, high-reliability RS-485 relay and digital input module designed for distributed control systems. With four isolated digital inputs and four relay outputs (two Form A and two Form C), it provides flexible control and monitoring capabilities for industrial automation, building management, and remote I/O applications. The module’s robust design includes optical isolation, surge protection, and dual watchdogs for enhanced reliability. Its compatibility with both ASCII and Modbus RTU protocols ensures seamless integration into existing control networks. The EX9060D’s compact form factor, wide power range, and extended temperature tolerance make it an ideal choice for demanding industrial environments requiring dependable digital I/O performance.