I/O Plexer Repeater Manual

Repeater
MANUAL
I/O Plexer Repeater
January 2005
Copyright
Copyright 2004-duTec inc. All rights reserved. However, any part of this document
may be reproduced, provided that duTec inc. is cited as the source. The contents of
this manual and the specifications herein may change without notice.
Trademarks
The duTec logo and I/O PLEXER and I/O Plexer Repeater are trademarks of duTec
inc.
Notice to the User
The information contained in this manual is believed to be correct. However duTec
inc. assumes no responsibility for any of the circuits described herein, conveys no
license under any patent or other right and makes no representations that the circuits
are free from patent infringement. duTec inc. makes no representation or warranty
that such applications will be suitable the use specified without further testing or
modification.
DuTec inc. general policy does not recommend the use of its products in life
support applications where failure or malfunction of a component may directly
threaten life or injury. It is a condition of sale that the user of duTec inc. products in
life support applications assumes all risk of such use and indemnifies duTec inc.
against all damage.
Warranty
duTec inc. warrants its products to be free of defects in materials and workmanship
for a period of two (2) years from the shipment date. DuTec inc., at its option, will
repair or replace all material found to be defective. All repair or replacement must
be performed by duTec inc. personnel. Any parts determined by duTec inc. to be
defective as a result of abuse, misuse or attempts to repair will be repaired at the
expense of the customer. DuTec inc. will not be held liable for any consequential,
incidental, or special damages.
I/O Plexer Repeater
January 2005
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Compatibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Communications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Response Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Easy Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Built in Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Communications Watchdogs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ungradable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Available I/O Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-1
1-1
1-1
1-2
1-2
1-2
1-3
1-3
1-3
1-4
Physical Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Package . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-4
1-5
1-5
1-5
Ordering Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 5
Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 5
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Digital Expander . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1
2-1
2-1
2-2
Linking the two I/O Plexer Repeaters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Link via RS-485 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Link via RS-422 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Link via modem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adding Digital Expanders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-3
2-4
2-5
2-6
2-7
Installing the I/O Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 8
Analog outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 15
Digital Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 16
Digital outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 17
Chassis Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Baud rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Setup pushbutton . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sequential display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Input/ output separators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Baud Rates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Network type switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Modem Jumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1
3-1
3-1
3-1
3-2
3-3
3-3
3-3
Changing setup parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 3
Unit number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 3
Pushbutton . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 3
Table of Contents
Sequential display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 4
Communication Verification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 5
Hardware error codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 5
Introduction 1
Overview:
In applications such as remote process monitoring, factory automation, and energy
management, a variety of signals must be transmitted over long distances. Instead of requiring
expensive, multi-conductor sensor wiring for each signal, cabling costs can be reduced
significantly by using a pair of I/O Plexer Repeaters and a single communications circuit.
Often called “wire savers” or “Cable concentrators” I/O Plexer Repeaters replace expensive
and noise prone long distance wire runs.
One I/O Plexer repeater concentrates sensor signals into serial data. The other recreates the
individual signals at a second location. Special firmware eliminates the need for a host
computer. Data flow is bi-directional, meaning that signals can be passes in either direction.
Data checksumming is automatically employed to ensure data integrity.
Capacity:
One pair of I/O Plexer Repeaters can interface 16 analog and digital signals in any
combination. With optional digital expanders, up to 48 more digital signals can be added for a
total of 64 I/O channels.
Compatibility:
I/O Plexer Repeaters use DuTec I/O modules to match signal requirements exactly. With a
direct interface to sensors, no external signal conditioning is required. Furthermore, all DuTec
modules feature total electrical isolation, both module to logic and module to module.
Analog modules are available to measure:
!
!
!
!
Millivolts DC to hundreds of volts AC
Milliamps DC to amps AC
Frequency to tens of kHz
Temperature with all popular thermocouples and resistance temperature
devices
A full range of industry standard digital modules is available for AC, DC, and dry contact
inputs and outputs to hundreds of volts.
1-1
Introduction 1
I/O Plexer Repeaters can be used to convert signals from one type to another. For example, a
thermocouple at the remote site can be converted to a standard process current (4-20mA)
signal at the local site.
Communications:
DuTec supports several standards for transmitting serialized I/O data between I/O Plexer
repeaters. In addition to hard wiring, built in modem control lines allow the use of telephone,
fiber optic, and radio modems at baud rates to 38,400.
Maximum Distance
Serial Link
Feet
Meters
RS-232
50
15
RS-422
5,000
1,524
RS-485
5,000
1,524
Modem
Unlimited
Unlimited
Response Time:
Under full load (sixteen analog and 48 digital signals), the average response time between an
input event and resulting output is less than 250mS @9600 Baud.
Easy Setup:
The I/O Plexer Repeater has its own power supply, no need to purchase or reserve space for
an external supply. A push-button and on board LED indicator configure the baud rate and
Input/ Output separators. Removable terminal strips allow the attachment/ removal of
multiple cable sets in one step. This modularity greatly reduces troubleshooting and upgrade
delays.
1-2
Introduction 1
Built in Diagnostics:
On power up, the unit self-tests for system faults and reports via a sequential display. Should
hardware or firmware fail, an onboard hardware watchdog provides safe shutdown by turning
off all outputs.
Communications Watchdogs:
The I/O Plexer Repeater can be instructed to implement alarm and failsafe states in the event
of a communication failure.
Ungradable:
If the application evolves to a centralized or distributed control network, I/O Plexer Repeaters
can be returned to the factory to be converted into standard I/O Plexers for a fraction of the
cost of a new unit. This means that the I/O Plexer Repeater hardware can be “recycled” into a
fully compatible I/O system for use with a standard MMI or SCADA package.
1-3
Introduction 1
Available I/O Modules
Analog inputs, 12 Bit
Frequency
IF10K-B
IF2.5K-L
IF5K-L
IF10K-L
Voltage
IV25M
IV50M
IV100M
IV1
IV5
IV5B
IV10
IV10B
IVAC
IVAC-A
Analog Outputs, 12 Bit
Voltage
Input 300Hz-10Khz
Input 0-2.5Khz
Input 0-5Khz
Input 0-10 KHZ
Input 0-25mV
Input 0-50mV
Input, 0-100mV
input 0-1V
Input 0-5 V
Input bi-polar ±5V
Input 0-10V
Input Bi-polar ±10V
Input 28-140 Vac
Input 56-280 Vac
Current
II420
Input 4-20 mAdc
IIAC5
Input 0-5Aac
Thermocouple
ITCE
Type E 0° to 435°C
ITCJ
Type J 0° to 700°C
ITCJ-1
Type J -80° to 750°C
ITCK
Type K -100° to 924°C
ITCK-1
Type K -110° to 1250° C
ITCR
Type R 0° to 960° C
ITCR-1
Type R 0° to 1760° C
ITCS
Type S 0° to 1034° C
ITCS-1
Type S 0° to 1760°C
ITCT
Type T -200° to 224° C
ITCT-1
Type T -120° to 400° C
ITCT-2
Type T 0° to 150° C
RTD
ITR100
100 Ohm PT -50° to 350°C
ITR100-1
100 Ohm PT 0° to 100°C
Type 590
Temperature Sensor
ITP590
-188.4° to 150°C
ITP590-1
-50.0° to 150°C
* When Selecting A power supply for the
system, assume 25mA for standard digital
modules and 100mA for modules marked
With an *
** The IDC5Z
Module is used for low-level
signals and will pass signals at the rate of
10Khz The I/OPlexer however is limited by
Communications baudrate.
OV1
0v5
0v10
Output 0-1V, self sourcing
Output 0-10V, self sourcing
output 0-10V, self sourcing
Current
01420
Digital
AC
IAC5
IAC5A
DC
IDC5D
IDC5NP
Digital
AC
Output, 4-20mA Self-Sourcing
into 275 Ohm Load.
Inputs
Input 90-140Vac
Input 180-280Vac
Input 3-32 VDC fast>500Hz
Input 10-32 Vdc, 15-32
Nonpolar
Outputs
OAC5
OAC5A
OAC5A5
Output 12-140 Vac, 3.5A
Output 24-280Vac, 3.5A
Output 24-280Vac 3.5A NC
OAC5J
DC
ODC5
ODC5A
ODC5R
Special
IDC5S*
Output 20-280Vac, 6.0A
IDC5Z*
SPS-1*
TIO1
Support
Fuses
FMP-06
FMP-1
FMP-3
FMP-5
Physical Characteristics:
1-4
Output 5-60 Vdc, 3.5A
Output 4-200Dc, 1.0A
Electro-Mechanical 0.5A Relay Form A NO
Purpose
Dry input contact sense, built in
isolated source
Input±200mV, 0-10Khz
(digital)**
Sensor power supply 18-24Vdc, 30mA
Digital Input/output Test Module
with field switch and LED
Products
Fuse Assy 0.062A
Fuse Assy, 1A
Fuse Assy, 3A
Fuse Assy 5A
Introduction 1
Power
Standard
85-132 VAC @30W
(47-440 Hz)
Option /E, /E5
Environment
Option /B
10-16 VDC @35W
Option /C
18-36 VDC @35W
Temperature
Humidity
Package
105-256 VAC @23W/39W
(47-440Hz)
0-60°C
95% non-condensing
Type
Stainless Steel
Length
17.25 in. (44 cm)
Width
5.0 in. (12.7cm)
Height
3.5 in. (8.9cm)
Weight
4 lbs. (1.8kg)
Ordering Information:
Specify duTec products by model number e.g.,
IOP-RAD
I/O Plexer repeater for analog and digital signals
IOP-RD
I/O Plexer repeater for digital signals only
Options are specified by a series of suffixes to the model number, preceded by a slash. Power
supply options are noted above. To expand signal capacity beyond 16, the following options
allow the use of the I/O Plexer repeater with digital expanders. For example,
IOP-RAD/3+ Allows the use of one to three digital expanders on an analog capable I/O
Plexer repeater.
IOP-RD/B Specifies a digital only I/O Plexer Repeater with a 12 VDC compatible power
supply.
1-5
Introduction 1
1-6
Installation 2
Installation:
In a wall mounted enclosure the I/O Plexer Repeater can be mounted horizontally or
vertically. Horizontal installation is good practice as it makes the best use of natural
convection.
Figure 2-1 below shows the outline of the I/O Plexer Repeater. Using the keyhole slots, the
unit can be mounted with 2-#10 screws on 16.5" centers. Using the corner holes, the unit can
be mounted with 4-#6 or #8 round head or pan head screws located on a 3.5" X 16.5" grid.
Hole locations in relation to the overall dimensions are shown below. Both the I/O Plexer
repeater and the digital expander have the same mounting dimensions.
Corner Mounting
4 #6-32 Screws
5.0
Slot Mounting
2 #10-24 Screws
3.5
2.25
.5
.375
16.5
17.25
Figure 2-1 I/O Plexer footprint
Power Wiring:
Power connections are made at the 3 position terminal block located on the right end of the
I/O Plexer Repeater. No. 8 captive wire clamps accept 10-16 AWG wire or spade lugs. The
terminal block cover need not be removed to install wiring.
2-1
Installation 2
AC Wiring
DC Wiring
I/O Plexer Repeater Power supply
terminal block
Figure 2-2 Power wiring
The center terminal block position, adjacent to the letter G on the end of the I/O module
board, is chassis/ earth ground which is connected to the I/O Plexer Repeater case.
Standard 85-132 VAC, 47-440 Hz and option /E5 105-265 VAC 47-440Hz Operation.
Following power wiring conventions(AWG)
Black wire to terminal marked H (hot)
White wire to the terminal marked N (neutral)
Green wire to the terminal marked G (chassis/ earth ground)
Option /B or /C 10-30 VDC Operation
+ of the power source to the terminal marked H
- of the power source to the terminal marked N
Earth Ground, where available to the terminal marked G
Digital Expander
The I/O Plexer Repeater Digital Expander (IOP-DE) Receives its power and signals from the
I/O Plexer Repeater via the included 24 pin keyed ribbon cable (duTec part #CE-24) No other
power wiring is required.
2-2
Installation 2
Linking the two I/O Plexer Repeaters:
In order for two I/O Plexer Repeaters to share their data, they must be linked via a serial
connection. This link can be hard-wired using either an RS-422 or RS-485 twisted pair
connection where the wire run between devices is less than 5000 Feet. In situations where
distances are greater than 5000 feet or circumstances do not allow additional wire to be
installed; RS-232 Radio or telephone modems may be used. In any event, the appropriate
transmitter of the I/O Plexer Repeater will be connected to a suitable receiver of the other I/O
Plexer Repeater as shown in figure 2-3.
IOP-RAD
Temperature
IOP-RAD
Inputs
Strip Chart
Outputs
Lamp
Alarm
Level Switch
Meter
Outputs
Inputs
Dial
Rx
Tx
Serial
Link
Tx
Rx
Figure 2-3 Communications link
2-3
Installation 2
Link via RS-485
Figure 2-4 Link via RS-485
Figure 2-4 shows one individually shielded twisted pairs of AWG 24 (such as Belden 8162)
with the shields connected between unit grounds. The overall isolated shield should be
connected to ground in one place only. In a perfect world with no electrical noise and equal
ground potentials everywhere the ground connection is not required. Not using the ground
connection can lead to costly debugging.
These connections, which require the cover to be removed, are made by placing a 1/4 inch
stripped wire into the openings of the wire clamp terminal block and tightening the screw.
This block is socketed for easy removal.
An alternative means for network connection is to use the 10 pin male connector located
behind the clamp terminal block. This connector mates with Molex shell, number 50-57-9005,
and used pins, 16-02-0103
In addition to the Host to I/O Plexer Repeater wiring the installer should confirm that the 8
switches are set in the correct positions (all on or up). In all cases, the switches marked “pullup” in the diagram in page 3-1 should be left in the “on” position.
2-4
Installation 2
Link via RS-422
Figure 2-5 Link via RS-422
Figure 2-5 shows two individually shielded twisted pairs of AWG 24 with an overall isolated
shield (such as Belded 8162) with the internal shield connected between unit grounds. The
overall isolated shield should be connected to earth ground in one place only. In a perfect
wold with no electrical noise and equal ground potentials, the signal ground connection would
not be required. Not connecting signal ground however, frequently leads to costly debugging.
These connections, which require the cover to be removed, are made by placing a 1/4 inch
stripped wire into the openings of the wire clamp terminal block and tightening the screw.
This block is socketed for easy removal.
An alternative means for network connection is to use the 10 pin male connector located
behind the clamp terminal block. This connector mates with Molex shell, number 50-57-9005,
and used pins, 16-02-0103
In addition to the serial link wiring the installer should confirm that the 8 switches are set in
the correct positions (on or up). The switches marked”pull-up” in the diagram on page 3-1
should be left in the “on” position.
2-5
Installation 2
Link via modem:
Figure 2-6 Link via Modem
Two handshake control lines are provided on the I/O Plexer Repeater for interfacing to
modems. They are request to send (RTS) and Clear to send (CTS).
An active high RTS signal from the I/O Plexer Repeater advises the modem that data is
available. When the modem is ready to accept data, it places its CTS line active high to the
I/O Plexer Repeater thus initiating the data exchange.
In addition to the modem to I/O Plexer Repeater wiring the installer should confirm that JP3
(RTS/CTS Jumper) is positioned as shown in figure 2-10. Jumper JP5 (RTS/CTS for the local
RS-232 port), should remain in the horizontal position unless the RTS/CTS pair is needed in
the device connected to the local RS-232 port. A cable for most modem applications, the IOPRT cable, is available from duTec.
The switches marked “Pull up” in figure 3-1 should be left in the “on” position.
2-6
Installation 2
Adding Digital Expanders:
Figure 2-15 Digital Expanders
Up to three Digital expanders may be connected to each side of an I/O Plexer Repeater
system. These chassis are attached to the main unit via a ribbon cable supplied with the
Digital Expander. Normally, power is supplied through this cable. In some circumstances,
however, the Digital Expander is purchased with an optional power supply. If so equipped,
the installer must provide the necessary power connections as well (see page 2-2).
Digital expanders are configured during the main chassis’ normal setup procedure.
2-7
Installation 2
Installing the I/O Modules:
The I/O Plexer Repeater system is made up of a communications link with an I/O system
located at each end. At one end of this link is a main I/O chassis designated UNIT O at the
other end there is a similar I/O chassis designated UNIT1. Installed on these chassis are
individual I/O Modules designed to handle analog or digital, input or output signals. For every
analog input located on UNIT O, there is a corresponding analog output on UNIT 1 and vise
versa. Naturally this is true for digital modules as well.
In addition to the main I/O chassis, an I/O Plexer Repeater system may include additional I/O
chassis called digital expanders. These chassis allow up to 48 additional digital only I/O
signals to be transmitted over the serial link.
When installing the system, place the chassis designated UNIT O in the location having
the most output signals.
Certain guidelines must be followed when installing I/O modules on the I/O Plexer repeater
chassis. In particular the inputs must be grouped separately from the outputs on each I/O
chassis. Using the worksheets found in the next four pages, place the desired I/O modules in
the indicated positions.
The following worksheets will be used when setting the necessary input/ output separator for
UNIT O.
2-8
Installation 2
UNIT O
Mod #
1)
2)
3)
4)
Main
Input/
Output
Chassis
UNIT 1
Module PN
Mod #
Main
Output/
Input
0
0
1
1
2
2
3
3
4
4
5
5
6
6
7
7
8
8
9
9
10
10
11
11
12
12
13
13
14
14
15
15
Chassis
Module PN
Install all analog input modules for UNIT O beginning with module #0 then #1
and so on. If none were used, skip this step.
Install all digital input modules for UNIT O beginning with the next available
module position. If none are used, skip this step.
Repeat step 2 for the analog output and digital output modules.
Install the modules in UNIT 1 which are to be matched with those in UNIT O. Be
sure that each input in UNIT O is paired with a corresponding output in UNIT 1.
Likewise for the outputs.
2-9
Installation 2
UNIT O 1st
Expander
Chassis
UNIT 1 1st
Mod #
Input/
Output
Module PN
Mod #
Expander
Input
/Output
0
0
1
1
2
2
3
3
4
4
5
5
6
6
7
7
8
8
9
9
10
10
11
11
12
12
13
13
14
14
15
15
Chassis
Module PN
1)
Install all digital input modules for UNIT O beginning with module #0 then #1
and so on. If none were used, skip this step.
2)
Install all digital output modules for UNIT O beginning with the next available
module position. If none are used, skip this step.
3)
Install the modules in UNIT 1 which are to be matched with those in UNIT O. Be
sure that each input in UNIT O is paired with a corresponding output in UNIT 1.
Likewise for the outputs.
2 - 10
Installation 2
UNIT O
2nd
Expander
Chassis
UNIT 1
Mod #
Input/
Output
Module PN
Mod #
2nd
Expander
Input
/Output
0
0
1
1
2
2
3
3
4
4
5
5
6
6
7
7
8
8
9
9
10
10
11
11
12
12
13
13
14
14
15
15
Chassis
Module PN
1)
Install all digital input modules for UNIT O beginning with module #0 then #1
and so on. If none were used, skip this step.
2)
Install all digital output modules for UNIT O beginning with the next available
module position. If none are used, skip this step.
3)
Install the modules in UNIT 1 which are to be matched with those in UNIT O. Be
sure that each input in UNIT O is paired with a corresponding output in UNIT 1.
Likewise for the outputs.
2 - 11
Installation 2
UNIT O
3rd
Expander
Chassis
UNIT 1
Mod #
Input/
Output
Module PN
Mod #
3rd
Expander
Input
/Output
0
0
1
1
2
2
3
3
4
4
5
5
6
6
7
7
8
8
9
9
10
10
11
11
12
12
13
13
14
14
15
15
Chassis
Module PN
1)
Install all digital input modules for UNIT O beginning with module #0 then #1
and so on. If none were used, skip this step.
2)
Install all digital output modules for UNIT O beginning with the next available
module position. If none are used, skip this step.
3)
Install the modules in UNIT 1 which are to be matched with those in UNIT O. Be
sure that each input in UNIT O is paired with a corresponding output in UNIT 1.
Likewise for the outputs.
2 - 12
Installation 2
Analog Inputs:
Modules should NEVER be installed or removed while power is applied to the I/O Plexer
Repeater.
Note: Analog modules normally run hot to the touch
Correct polarity connections are essential to proper operation of all analog inputs.
Connections to terminals marked with a “+” must be more positive than the terminals marked
with a “-“. Thermocouples and RTD’s are connected directly to the I/O modules with special
connectors which insure correct polarity.
Module status indicators are On dimly, when wired correctly, and monitoring a valid signal.
The indicator light may be On brightly, off, or flicker otherwise.
Figure 2-7, figure 2-8 and figure 2-9 show the wiring for various types of analog inputs. With
the exception of thermocouples and RTD’s, connections are made via the black terminal strip.
In the case of thermocouple RTD’s, connections are made directly to the module, mating
connectors are included. There must be nothing connected to the screw terminals
corresponding to these module positions. The source of analog inputs is external to the I/O
Plexer Repeater in most circumstances. Exceptions are those of RTD and Type 590
temperature input modules where source excitation is supplied within the module.
Figure 2-8 AC current and voltage wiring
2 - 13
Installation 2
Figure 2-9 Analog Frequency, Voltage, and current input wiring
Figure 2-10 Temperature input wiring
2 - 14
Installation 2
Analog outputs:
Modules should NEVER be installed or removed while power is applied to the I/O Plexer
Repeater.
Note: Analog modules normally run hot to the touch
Both voltage and current output modules provide their own isolated power output. This
eliminates the need for external power supplies and insures electrical isolation between each
output. This also makes it possible to wire voltage outputs in series to obtain larger voltage
swings (consult application support).
Module status indicators blink briefly when outputs are updated. It should be noted that the
status indicator only reflects the TTL data stream to the modules. This in of itself does not
indicate the actual value of the output signal. Output can only truly be verified by monitoring
the device to be controlled using a multimeter, oscilloscope, or employing an analog input
module as a feedback tool.
Figure 2-11 Analog Voltage and current output wiring
OI420 analog output modules will drive up to 275 ohms. If the loop resistance exceeds 275
ohms, and external power supply must be added as shown in figure 2-11. Correct polarity is
essential.
2 - 15
Installation 2
Digital Inputs:
Modules should NEVER be installed or removed with power applied to the I/O Plexer
Repeater.
The source of the discrete signal to be monitored is external to the I/O Plexer Repeater in
most circumstances. The IDC5S digital input dry contact sense module is an exception. It
provides its own current for sensing contact closure. Therefore, an external supply is not
needed. In fact, they can be DESTROYED if an external source is connected.
The IDC5 and IDC5D input modules are polarity sensitive and operate only when the “+”
terminal is more positive than the “-“ terminal, Polarity does not affect the performance of the
IAC5, IAC5A, or the IDC5S input modules.
Because the field sides of input modules are totally isolated from each other, like polarities
can be wired common to make use of a single power supply.
The wiring and operation of digital input modules can be verified by closing individual input
sensing contacts and observing the change on the nodule status indicators. They are On when
the module input circuit is energized.
Figure 2-12 Digital Input Wiring
2 - 16
Installation 2
Digital outputs:
Modules should never be installed or removed while power is applied to the I/O Plexer
Repeater.
ODC5, ODC5A, OAC5, and OAC5A digital output modules are used to switch external
power supply loads on and off.
Because they contain a protective reverse diode, the ODC5 and ODC5A output modules are
polarity sensitive and operate correctly only when the “=” terminal is more positive than the
“-“ terminal. A DC digital output module connected backwards conducts current through its
protective diode and appears to be uncontrollable, it is. Polarity does not affect the
performance of OAC5 and OAC5A digital output modules.
Because the field sides of output modules are totally isolated from each other, like polarities
can be wired common to make use of a single power supply.
It should be noted that the status indicator only follows the logic instruction to the modules
and does not show that the module, its fuse, or external power is present. Outputs can only be
truly verified by monitoring the output with a multimeter, oscilloscope, or by employing a
digital input module as a feedback tool.
Figure 2-13 Digital output Wiring
2 - 17
Installation 2
2 - 18
Setup 3
Chassis Setup:
Figure 3-1 Connectors, Switches, and Indicators
During the setup phase of an I/O Plexer Repeater system, the main chassis are given specific
values for unit identity, network baud rate, and in the case of UNIT O, where the separation
between input and output modules is. A momentary pushbutton and seven segment display
provide access to these parameters. Figure 3-1 shows the location of these components labeled
setup pushbutton and sequential display.
During normal operation, the sequential display shows the following characters one at a time.
Display cycle for UNIT O:
Display cycle for UNIT 1:
3-1
Setup 3
Unit Number:
Each I/O Plexer Repeater is set to either UNIT O or UNIT 1. The sequential display indicates
Echo = followed by the unit number. When shipped from the factory, I/O Plexer Repeaters are
configured as UNIT 1 (Echo = 1).
Input/ Output Separators:
Each UNIT O will require up to four input/ output separators to be set. This identifies which
modules are inputs and which are outputs for each chassis being used. For example, UNIT O
could consist of its main chassis as well as up to three digital expander chassis. Upon
establishing communications, UNIT O Will automatically configure the UNIT 1 separator
appropriately.
The first I/O separator, following the o in the sequential display, is the UNIT O main chassis
I/O separator. It should be set equal to the hex value of the lowest numbered module position
containing an output module (analog or digital) on the UNIT O main chassis. If UNIT O is full
(all 16 positions) of outputs, set the I/O separator to O. Refer to the worksheet found on page
2-9.
The second I/O separator, following the ° in the sequential display, is the first digital
expander I/O separator. It should be set equal to the lowest numbered module position
containing a digital output module on the first expander chassis. Refer to the worksheet on
page 2-10. If the first digital expander is not being used, disregard this value.
The third separator, following the 1 in the sequential display, is the I/O separator for the
second digital expander. It should be set equal to the lowest numbered module position
containing a digital output module on the second expander chassis. Refer to the worksheet
found on page 2-11. If the second digital expander is not being used, disregard this value.
The last I/O separator, following the 11 in the sequential display, is the third digital expander
I/O separator. It should be set equal to the lowest numbered module position containing a
digital output module on the third digital expander chassis. Refer to the worksheet on page 212. If the third expander is not being used, disregard this value.
3-2
Setup 3
Baud Rates:
Any one of the standard baud rates of 300, 600, 1200, 2400, 4800, 9600, 19200, or 38,400 can
be used for the serial network communications. The sequential display indicates the letter H
followed by a baud rate divided by 100. As shipped the I/O Plexer Repeater are set up for
9600 baud, the display will indicate H 096.
Network type switch:
The I/O Plexer Repeater network switch must be set to the last unit position (as in figure 3-1).
The digit after the L in the sequential display represents how the network switch under the
cover plate is set. This should always be set to “last unit” therefore the sequential display
should always be L 3.
Note: The seven segment display will not reflect a switch position change until power to the
unit has been cycled.
Modem Jumpers:
If modems are not being used, the jumpers should remain in place, as shipped, in a horizontal
position (see page 2-6)
Changing setup parameters
During setup, the user may need to change the unit number, serial link baud rate, and the
input/ output separator positions on UNIT O. The pushbutton located under the removable
cover is used to change these parameters. The pushbutton causes the adjacent LED to flash
each time it is pushed. Any changed values are automatically saved in non-volatile EEPROM.
During the diagnostic test period following the application of power, the sequential display
shows: GoGoGo = Flashing the push button LED once when the = appears, places the unit in
setup mode. The value of each setup<< Index will generate here >> character can be changed
as they appear in sequence, by pressing the pushbutton. The display will continue to cycle
through the setup sequence until there is a full cycle with no changes. The I/O Plexer Repeater
then stores all values in EEPROM for automatic use following a power cycle. If desired
changes were not implemented correctly, line power can be recycled and setup via pushbutton
can be repeated as required.
3-3
Setup 3
Communication Verification:
Most startup problems are related to the communications link. The lowest bar of the left 10
bar display (marked recv) blinks when there is serial data traffic being sent to this I/O Plexer
Repeater from the other unit. The LED merely indicates serial data. It does not indicate that
this data is valid nor at the proper baud rate. The lower bar on the right 10 bar display
(marked trans) blinks each time this I/O Plexer Repeater sends data to the other unit. When
the network is first activated, UNIT O polls UNIT 1 periodically until it answers. When the
link is established, the two units will communicate in a back and forth manner continuously.
If either side experiences failure, such as power loss, UNIT O will return to periodically
polling UNIT 1 until the link is re-established and/ or power is returned to the unit.
Hardware error codes:
When the I/O Plexer Repeater is initially turned on, it goes through internal self test. If
anything is not correct, the appropriate error code will flash on the sequential display. Try
recycling power, if that does not resolve the error condition please call duTec technical
support at (800) 248-1632.
3-4
Index
Analog inputs, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 4, 2 - 13
Analog Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 4, 2 - 15
Baud rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 3
Cabling costs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 1
Chassis Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 1
Communications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 2
Communications Watchdogs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 3
Data integrity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 1
Digital Expander . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 2, 2 - 7
Digital expander . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 1
Digital expanders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 1, 1 - 5, 2 - 8
Digital Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 16
Digital Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 4, 2 - 17
Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 5
Footprint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 1
For UNIT 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 1
Host computer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 1
Input/ Output Separators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 2
Isolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 1
IOP-RAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 5
IOP-RD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 5
JP3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 6
JP5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 6
Local RS-232 port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 6
Modem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 2, 2 - 3, 2 - 6
Modem Jumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 3
Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 4
mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 1
Network type switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 3
Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 4
Package . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 5
Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 5
Power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 4
Power Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 1
Response Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 2
RS-232 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 2
RS-422 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 2, 2 - 3,2 - 5
RS-485 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 4
RT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 4
RTD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 13
RTS/CTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 6
Sequential display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 1
Serial connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 3
Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 4
Setup pushbutton . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 1
Signal conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 1
Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 4, 2 - 6
Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 4
Index
The local RS-232 port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 6
Thermocouple . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 4, 2 - 13
UNIT O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 8, 3 - 1
UNIT1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 8
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