Omega EZPLC Series Owner Manual

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EZPLC

Hardware Manual

Manual Part Number EZPLC-M

Revision A.1

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EZPLC

Hardware Manual

Manual Part Number EZPLC-M

Revision A.1

Re-Order from

Omegamation

TM

1-888-55-66342

1-888-55-OMEGA omegamation.com

WARNING!

Programmable control devices such as EZPLC are not fail-safe devices and as such must not be used for stand-alone protection in any application. Unless proper safeguards are used, unwanted start-ups could result in equipment damage or personal injury. The operator must be made aware of this hazard and appropriate precautions must be taken.

In addition, consideration must be given to the use of an emergency stop function that is independent of the

EZPLC.

The diagrams and examples in this user manual are included for illustrative purposes only. The manufacturer cannot assume responsibility or liability for actual use based on the diagrams and examples.

Trademarks

This publication may contain references to products produced and/or offered by other companies. The product and company names may be trademarked and are the sole property of their respective owners. EZAutomation disclaims any proprietary interest in the marks and names of others.

Manual part number EZPLC-M

© Copyright 2005, EZAutomation

All Rights Reserved

No part of this manual shall be copied, reproduced, or transmitted in any way without the prior written consent of EZAutomation. EZAutomation retains the exclusive rights to all information included in this document.

Designed and Built by AVG

4140 Utica Ridge Rd. • Bettendorf, IA 52722-1327

Marketed by EZAutomation

4140 Utica Ridge Road • Bettendorf, IA 52722-1327

Phone: 1-877-774-EASY • Fax: 1-877-775-EASY • www.EZAutomation.net EZPLC-M

Table of Contents i

Table of Contents

Cover/Warnings/Tradearks

Table of Contents ………………………………………………………..………….. i

EU Information ………………………………………………………..……………. ii

………………………………………………………..... ii

……………………………………………………….......... ii

………………………………………………..ii

Preventative Maintenance and Cleaning …………………………………….. ii

CHAPTER 1 - GETTING STARTED

Introduction

1.2 Purpose of the Manual………………………………………….. 1-3

1.3 Organization of the Manual…………………………………….. 1-4

1.4

1.5 Quick and EZ System Overview……………………………….. 1-7

1.6 EZPLC Part Numbering System……………………………….. 1-8

1.8 How to Design the Most Effi cient EZPLC System………….... 1-11

CHAPTER 2 - INSTALLATION

2.1 Safety Considerations………………………………………….. 2-2

2.2 Installation Considerations…………………………………….. 2-3

2.3 Electrical Considerations……………………………………..... 2-4

2.4 Sourcing (P type) and Sinking (N type) I/O…………………... 2-10

2.5 EZPLC Mounting………………………………………………... 2-12

2.6 EZIO Modules Positioning……………………………………... 2-13

2.7 EZIO Mounting and Wiring…………………………………….. 2-15

2.8 EZI/O Modules…………………………………………………... 2-17

CHAPTER 3 - SPECIFICATIONS, CPU OPERATION, PLC MODES

AND MEMORY MAPS

3.1 EZPLC Models and EZIO Modules……………………………. 3-2

3.2

EZPLC

CPU cations…………………………………………....

3-4

3.5 CPU Operation Modes…………………………………………...3-5

3.6

CPU

3.8 I/O Response Time………………………………………………. 3-9

CHAPTER 4 - MAINTENANCE AND TROUBLESHOOTING

4.1 Hardware Maintenance…………………………………………..4-2

INDEX i

ii Table of Contents

EU Information

EZPLC is manufactured in compliance with European Union (EU) Directives and carries the CE mark. EZPLC has been tested under CE Test Standard #EN55011, and is submitted for UL Certifi cation.

Please Note: Products with CE marks perform their required functions safely and adhere to relevent standards as specifi ed by EU directives provided they are used according to their intended purpose and that the instructions in this manual adhere to. The protection provided by the equipment may be impaired if this equipment is not used in accordance with this manual. Only replacement parts supplied by EZAutomation or its agents should be used.

Technical

Support

Consult EZPLC Editor Programming Software Help or you may fi nd answers to your questions in the operator interface section of our website @ www.

EZAutomation.net. If you still need assitance, please call our technical support at 1-877-774-EASY or FAX us at 1-877-775-EASY.

SELV Circuits All electrical circuits connected to the communications port receptacle are rated as Safety Extra Low Voltage (SELV).

Environmental

Specifi cations

Operating Temperature: -100 to +60 °C

Storage Temperature: -20 to +70 °C

Operating Humidity:

Air Composition:

10 - 95% R.H., noncondensing

No corrosive gasses permitted

Preventative

Maintenance and Cleaning

No special preventative maintenance is required.

Getting Started

In this chapter....

• Purpose of the Manual

• Organization of the Manual

• Quick and EZ System Overview

• EZPLC Part Numbering System

• Quick and EZ Start to Getting Familiar with EZPLC

• How to Design the Most Effi cient EZPLC System

1

1-2 Chapter 1 - Getting Started

1.1 Introduction

Welcome to EZAutomation’s new programmable logic controller, the

EZPLC.

EZAutomation is the newest addition to the AVG family, with a 37-year-old tradition of manufacturing more than 200 high value and most innovative automation products.

AVG, established in 1975, is an American group of companies comprised of Autotech, Uticor, and now EZAutomation. Since its inception, AVG has introduced more than 500 innovative new products, including PLS and

PLCs. We have more than 20 patents in Automation products and 15 new patents are pending.

Uticor, formerly Struthers Dunn Systems division, has been at the forefront of

PLCs, welding controls, message displays and operator interface technology since 1968. Uticor, in fact, was one of the early inventors of PLCs back in 1968. It held numerous patents on PLCs, then called Process Control

Computers.

The EZPLC’s innovation, fl exibility, cost-effectiveness and precision, comes from Uticor’s 37 years of PLC experience.

US Patent No.

3,761,882 issued to Uticor on

Sept 25, 1973

Describing the fi rst time use of programmable memories in PLCs.

Chapter 1 - Getting Started 1-3

1.2 Purpose of the Manual

This manual is presented with details and step-by-step information on Installation and Programming of a new EZPLC. It also covers the troubleshooting and maintenance of an existing setup, if present, and provides understanding on how to connect an EZPLC with other components in your control system.

This manual is a good reference guide for personnel who install EZPLCs as well as those who program them. If you understand programmable logic controllers in general, you can fi nd all the information you need to start and maintain your system in this manual.

Where should I Start?

If you are already familiar with basic PLC concepts, you may choose to start with Chapter 2, Hardware Installation. New customers may fi nd it more useful to get acquainted with the features of EZPLC fi rst. The Quick And

EZ Start to get familiar with EZPLC section of this chapter is also a good starting point, for both experienced and new users.

Where to get HELP - Technical Support

We make every effort to keep our manuals in line with the feedback from our customers. If you fi nd it diffi cult to locate what you are looking for, check the resources listed below for the topic you are looking for.

• Table of Contents: A listing of contents per chapter, at the

• Index: Index is an alphabetical listing of all key words located at the back of the manual.

• Topics

Each Chapter: At the beginning of each chapter

Although most of your questions will be answered within this manual, if you still need assistance, technical support is available at 1-877-774-EASY. Our voted best Tech Support Engineers are available Monday through Friday 6

A.M. to 12 midnight CST. You can also reach us at 1-563-650-8112 on the weekends for emergency tech support. We may not be able to provide you the level of support available during the week, but we would most likely be able to solve your emergency needs.

You can also visit our website for online resources and the latest product related information. Our web address is www.EZAutomation.net.


1.3 Organization of the Manual

The table below provides an overall description of the topics covered within this manual.

Chapter

1

2

Description

Chapter 1: Getting Started

Introduction; Purpose of the Manual; Quick and EZ System Overview;

EZPLC Part Numbering System; Quick and EZ Start to getting familiar with

EZPLC; How to design the most effi cient EZPLC system.

Chapter 2: Installation

Safety Considerations; Installation considerations; EZPLC Environmental and Power Specifi cations; Electrical considerations; Control Cabinet installation; Installing EZPLC Base; Base Mounting Dimensions; Power sources and Optical Isolation; EZIO Modules Positioning; EZIO Modules

Installation Overview.

3

Chapter 3: Wiring

EZPLC Models and Specifi cations; CPU Overview; CPU Hardware; PLC

Operation Modes; CPU Status indicators; Communication Ports; Battery backup; CPU Operation; I/O Response time; Scan time considerations;

Memory map.

4 Chapter 4: Maintenance and Troubleshooting




1.4 EZPLC System Overview

DC Input 10-28 VDC

8 pt

8 pt sink/source

High Speed

DC Output 10-28 VDC

8 pt sink or source, 0.5A

DC Combo 10-28 VDC

4 pt IN, 4 pt sink OUT

4 pt IN, 4 pt source OUT

4 pt IN, 4 pt High Speed IN

AC Input

8 pt 70-132 VAC

AC Output

8 pt 70-132 VAC

Not in M2 slot

AC Combo 70-132 VAC

4 pt IN, 4 pt OUT

*Not in M2

CPUs

Mounted underneath base

1. Standard w/ 2 serial ports

2. Enhanced w/ 2 serial ports and Ethernet

40MHz, 8192 Registers

64KB memory, 3ms scantime for 1K

M1 M3

M2 M4

Communication

Cards

Plugged onto the back of the base

1. DeviceNet

2. Profi bus

Bases

4 slots -

6 slots -

8 slots -

32 I/O, 110VAC, 24VDC

48 I/O, 110VAC, 24VDC

64 I/O, 110VAC, 24VDC

12 slots 96 I/O, 110VAC, 24VDC

* Plug-in 2x2x1 I/O modules with

Removable Terminal Block and

LED indicator in each I/O

Analog Input,

12 bit

8 channel IN, voltage

8 channel IN, current

M1 to M10

8 pt

Analog Combo, 12 bit

4 ch. IN, 4 ch. OUT

0-5 VDC or 0-10 VDC

0-20 mA or 4-20 mA

M1 to M4 only

Relay Output

4 pt OUT, 5-180 VDC

or 20-132 VAC, 1A

*Not in M2

Relay Combo

4 pt IN, 70-132 VAC

4 pt OUT, 5-180 VDC

or 20-132 VAC

4 pt IN, sink/source

4 pt OUT, 5-180 VDC

or 20-132 VAC *Not in

M2

Specialty

4 ch. Thermocouple IN

High speed counter with

1 or 2 encoders

AC/DC Combo

4 pt OUT, 10-28 VDC source, 4 pt OUT,

70-132 VAC *Not in M2

4 pt IN, 70-132 VAC,

4 pt OUT, 10-28 VDC

source

4 pt IN, 10-28 VDC

sink/source, 4 pt OUT,

70-132 VAC *Not in M2

Inserting an EZI/O Module Programming EZPLC Editor


1.5 Quick and EZ System Overview

The EZPLC family is the most innovative PLC in its class. These micro modular PLCs are smaller in size, but they are packed with high controlling power only found in high-end PLCs.

EZPLC Base

The EZPLC bases are available in four models for 4, 6, 8 or 12 slots and are capable of fl exibly incorporating 32, 48, 64 or 96 I/O points respectively. Every EZPLC model is available for either 24 VDC or 110

VAC power input. Every EZPLC has a built-in RS232 port (programming and HMI), RS-422 port (ASCII communications), CPU with or without

Ethernet (what we call our card engine), and slots for I/O modules.

Optional communication cards for DeviceNet Slave and Profi bus Slave can be utilized with every model as well (fi eld installable).

CPU (Card Engine)

There are two types of CPUs. The Standard CPU has two integrated

Serial Communication ports; while the Enhanced model comes with additional Ethernet connectivity. The CPU is located underneath the

Base. Both types of CPUs have 64KB of total program memory and a rich yet concise instruction set including drum sequencer, 32-bit fl oatingpoint calculations, ASCII In/Out and Data conversions. Scan time for 1K instructions is approximately 3 ms including all overhead.

I/O Confi guration

The EZPLCs can support a maximum of 32, 48, 64 or 96 I/O points on it’s

4, 6, 8 or 12 slot bases respectively.

I/O Modules

All EZPLCs utilize plug-in EZIO modules for its IO requirements. EZIO modules are not included with EZPLC bases and need to be purchased separately. All the bases in EZPLC series can be equipped with any

EZIO module with only minor restrictions on the type of EZIO modules that can be used in some of the I/O slots. EZIO modules are available for

DC, AC, Analog, Thermocouple, High speed counter and Relay type IO requirements. As you can see from the I/O tables on the preceding page, there are a number of Mix-n-Match I/O Modules. The patent pending

Mix-n-Match capability of EZIO makes it extremely fl exible to confi gure the I/O or EZPLC.


1.6 EZPLC Part Numbering System

EZIO Part Numbering System:

EZIO modules use a very easy and self-explanatory part numbering system. Let’s take a few examples to get you familiarized with the conventions used in part numbering:

Discrete Modules: with inputs.

•EZIO-4DCI4DCOP EZIO Module with 4 DC inputs and 4 DC type outputs P specifi es PNP Sourcing Type output

(N specifi es NPN Sinking type output).

•EZIO-4ACI4ACO EZIO module with 4 Analog inputs and 4

Analog outputs V specifi es voltage (C specifi es

Analog Modules:

•EZIO-4ANI4ANOV EZIO module with 4 Analog inputs and 4 outputs specifi

Similarly, all EZIO modules have intuitive and easy to remember part numbers. For a complete list of all the EZIO module’s part numbers and description, refer to Chapter 3.


1.7 Quick and EZ Start to Get Familiar with EZPLC

In this section we present a quick example of how you can setup your

EZPLC. You will see how EZ it is to setup an EZPLC, even if you are new to PLCs. This example is not intended to explain specifi c details needed to start-up your system. Rather, it provides a quick guide to give a broad picture of what is needed to power-up your EZPLC system.

Step 1 Check all System Components

It is always recommended to make sure you have all the right parts to

build your system. This is what you will need to get started:

• EZPLC Base (e.g. EZPLC-D-32)

• Discrete AC or DC EZIO modules*

(e.g. EZIO-8DCI and EZIO-8DCOP

• RS-232C Programming cable (P/N EZP-PGMCBL)*

• Screwdriver for I/O Module wiring (P/N EZIO-SCDRV)*

(You can also use your own 2.5mm blade screwdriver)

• EZPLC Editor Programming Software (P/N EZPLC-EDIT)*

• 24 VDC/120 VAC Momentary NO switch**

• 24VDC Power Supply assuming you have a DC Power EZPLC

* These items have to be purchased separately from

EZAutomation.

** EZAutomation does not sell this item.

You will also need a PC for programming EZPLC. It can be any IBM

or Compatible PC (486 or better) with a mouse and a separate serial

port, a CD-ROM Drive, and a Windows operating system (Standard

Windows 95/98/NT4.0/2000/XP) installed on it.

NOTE: If you purchased an

AC Power Base, everything else remains the same except for the use of 120 VAC in place of 24 VDC.

Step 2 Install I/O Modules

Insert EZIO module(s) into the base. Refer to the following I/O

EZIO-8DCI should be mounted at position M1 and EZIO-8DCOP at

M3. EZIO modules have a snap-on design to facilitate easy installation

and removal from the base slots. The I/O modules have two clips and

a Molex connector, which snap into the EZPLC Base.

• Hold the module in the thumb and index fi nger so that your

fi ngertips are on the clips (see image to the left)

• Snap the module onto the board so that clips are placed on the

• Make sure that the Molex connector is aligned to the female

counterpart on the base

• Push the module gently from the top to insert it completely until

you hear a clicking sound

Step Add I/O Simulation

Wire the Momentary switch as per the diagram and add an output

module.

Connect the power input wires into the EZPLC’s power terminals. Do

not apply power at this time.


Step 5 Install software on your PC

Load the CD included with the purchase of software (P/N EZPLC-

EDIT) into your computer’s CD-ROM drive and follow the on-screen

instructions. The software will install itself.

Step 6 Connect EZPLC to your PC

Connect your PC’s serial port to EZPLC’s RS232 port using the

programming cable (P/N EZP-PGMCBL). Mode DIP switch SW1

enables or disables the RS232 port on the PLC. Thus, SW1 must be in

the ON position in order to program the EZPLC. SW2 must be OFF.

SW3 and SW4 should be ON.

Step 7 Switch ON the Power

Apply power to the system and ensure the PWR indicator LED on the

EZPLC base is ON. If not, remove power from the system and check

Step Enter Program

1.Open the EZPLC Editor Software and click

on the Edit Program Off-Line (Write to

EZPLC Later) button.

2.Type the project name ‘demo’ in the Project

Name fi eld (as shown in the image on the

left). The EZPLC projects are saved as .lad

fi les in the PC.

3.Select the appropriate EZPLC I/O Base e.g.

‘4 Modules (EZPx-32).

4.Click on the Confi gure I/O button and select

the appropriate position for your EZIO

modules (e.g. ‘8 DC Inputs’ for M1 and I1-I8

for its address and ‘8DC Outputs’ for M3

position and O1-O8 for its address).

5.Enter following sample ladder program into

the EZPLC Editor.

a.Select “Relay/Boolean” type instruction set in the instruction toolbar (located on the right side of the

EZPLC Editor programming screen. b.Click on “NO Contact” and then click on the main ladder logic programming window to place it as shown on the following page.

c.Once placed on the ladder logic programming window, double-click on the icon and enter the tag name/ address as “I1”.


d.Similarly, click on “NO Coil” and place the instruction in

the ladder logic programming window. Select the tag

name/address as “O1”.

e.Click on shortcut to wire “NO Contact” and “NO Coil” as

shown.

6. Transfer the program to the EZPLC by pressing the Control + T

keys on your PC.

Step Test the Program

When you press the NO momentary switch, the LED on Input Module

M1 input #1 and on the output module M3 output #1 will turn ON.

When you release the switch, both LEDs will turn off.

Congratulations!

You have successfully written and tested your fi rst program in EZPLC.

1.8 How to Design the Most Effi cient

EZPLC System

When designing your control system, keep the following recommendations in mind to design the most effi cient and powerful EZPLC system:

1. Take Advantage of our Mix-n-Match EZI/O

One key advantage of using EZPLC is its extremely fl exible EZIO. In order to take full advantage of this feature, fi rst fi gure out the requirements for your control system. Figure out your most commonly used and most cost effective switches, solenoids, and sensors, etc. Once you have a good idea of all of these devices that you are going to use, then pick EZIO to match your confi guration instead of trying to match your confi guration to the available IO as you would do with most other PLCs. There is practically no confi guration of IO that EZPLC cannot handle. EZIO is available in effi cient blocks of 8 points with AC/DC combo modules, AC/DC with Relay, Analog combo and many more to match any confi guration.

Need fast response time for your control system? EZPLC has a fast scan time, an average of 3ms for 1K Boolean instructions and all other associated overhead. Even if your control system’s scan time spreads out to 5-6 ms based on the logic used, you can take advantage of our FAST interrupt inputs and subroutines. Use these inputs to match the precision of multithousand dollar PLCs.

With EZPLC, you will have the absolute peace of mind when picking EZIO modules for your control system. EZPLCs do NOT require any power budgeting whatsoever. You can practically pick out any EZIO module in any combination without having to worry about power budgeting.


Before you start designing your control system, just take a couple of moments to understand EZPLC’s rich yet concise instruction set. It has features like Drum, data conversion, and marquee instructions to save you extensive programming. A Relay Ladder Logic program (RLL) designed in another PLC might require 100 rungs where EZPLC can perform the same functionality by utilizing subroutines and using our patent-pending Free Flow

Logic in just a couple of rungs.

Regardless of the size of the EZPLC you purchased, all models have an abundant 64KB of total memory available. With this amount of available memory, you can now design practically any size of RLL program without ever having to worry about memory shortage. You can create large databases, huge recipes, and data acquisition with this amount of memory in your PLC.

There is no shortage of the numbers of variables (tags) and registers in the

EZPLC. Therefore, you do not have to worry about running out of registers and accordingly plan your design.

Installation

In This Chapter....

• Installation Considerations

- Physical Control Panel Layout

• Electrical Considerations

- Understanding of Electrical Noise,

Wiring Shielding

AC Noise

- Isolating DC Power Supplies

• Sourcing/Sinking Concepts

• EZPLC Mounting

• EZIO Modules Positioning

• EZIO Mounting and Wiring

2

2-2 Chapter 2 - Installation

2.1 Safety Considerations

Please follow all applicable local and national codes to ensure maximum safety of the equipment and personnel. The installation and operational environment must be maintained per the latest revision of these codes.

You are responsible to determine the codes to be followed, and to verify the compliance of equipment, installation, and operation with the latest revision of these codes.

Plan for Safety

It is an absolute must to follow all applicable sections of:

• The National Fire Code

• The National Electrical Code (NEC)

• The National Electrical Manufacturer’s Association (NEMA) codes.

Local regulatory and government offi ces usually provide excellent help to determine which codes and standards are necessary for safe installation and operation.

Safety Techniques

Safety is the most important element of a proper system installation. Adhering to these safety considerations ensures the safety of yourself and others, as well as the condition of your equipment. We recommend reviewing the following safety considerations:

The main power switch should be easily accessible to the operators and maintenance personnel. It is important to make sure that all other sources of power including pneumatic and hydraulic are de-energized before starting the work on a machine or process controlled by a

PLC.

Most of the machines are installed with safety circuits, like Limit switches, Emergency stop push buttons, and Interlocks. These circuits should always be hard-wired directly to the PLC. These devices must be wired in series so that when any one device opens, the PLC is automatically de-energized. This removes power to the machine.

These circuits should not be altered in any case, since serious injury or machine damage could result.

3) Fail-Safe Operation

Our products are not fault-tolerant and are not designed or intended for use as on-line control equipment in hazardous environments requiring fail-safe performance, such as in operation of nuclear facilities, aircraft navigation or communication systems, air traffi c control, direct life-support machines, weapons systems, clutch control systems on presses, in which the failure of the product could lead directly to death, personal injury or severe physical or environmental damage. External fail safe and/or redundant components are required to make your control system Fail-safe.

Chapter 2 - Installation 2-3

2.2 Installation Considerations

EZAutomation products have been designed and tested for operation in the most demanding industrial environments. Modern solid-state industrial controls are complex electronic equipment that operate at low levels of voltage and current, coexisting with components that operate at much higher levels of power. The difference in operating power characteristics between the high and low power control devices creates the possibility of unwanted signals being generated causing interference. The interference, which is a by-product of electrical noise, is not present at all times. However, it appears at random and during brief periods of time it can cause disruptions and errors in the operation of a control system.

Enhancement of a system’s noise level immunity, and its tolerance to other environmental hazards can be accomplished by following proper system installation guidelines. The recommendations are of a general nature and constitute good industrial installation practice.

General Environmental Installation Considerations

Avoid installing EZPLC in areas where the following conditions may exist:

• Environmental temperatures above or below those specifi ed by the

EZPLC

• Prolonged exposure to humidity and liquids which may be sprayed or splashed on the equipment

• Dusty environments where airborne particles may accumulate on equipment causing reduction of heat dissipation, and reduction in effective electrical spacing between components

• Areas of excessive vibration

• Areas of high-radiated electrical noise, such as near fi elds of transmitting antennas and areas in close proximity of arc welding

stations

Environmental Specifi cations

The following table lists the environmental specifi cations that generally apply to the EZPLC Bases and EZIO modules. Please refer to the appropriate I/O module specifi cations in the EZIO User Manual (P/N EZIO-M).

Parameter

Operating Temperature

Storage Temperature

Humidity

Vibration Resistance

Shock Resistance

Electrical Noise

Atmospheric Conditions

Ratings

-10 to 60 °C

-20 to 70 °C

10 to 95% Relative Humidity, Non-condensing

5 to 55 Hz, 2g for 2 Hours in X, Y, and Z Axes

10g for under 12 ms in X, Y, and Z Axes

NEMA ICS 2-230 Showering Arc, ANSI C37.90a SWC, Level C

Chattering Test

Non-corrosive gases


Agency Approvals

Your application may require Agency approval*. EZPLC’s agency approvals are:

• UL (Underwriter’s Laboratories, Inc)*

• CUL (Canadian Underwriter’s Laboratories, Inc)*

• Approvals in process. Check our website www.EZAutomation.net for the latest information.

Physical Layout of EZPLC In Control Cabinets

When possible, cabinets housing electronic equipment should be designed with provisions for natural or forced ventilation to facilitate heat dissipation.

Observe the following rules for cabinet installation:

• Heat generating equipment (power supplies and other heat inducing components) should be installed toward the top of the cabinet. The lower space in the cabinet is cooler than the top area.

• Install heat-sensitive components in the lower section.

• Provide enough space between components to allow a free fl ow of air for better heat dissipation.

• Provide the maximum possible physical separation between solid state and electromechanical controls. If possible, the electromechanical controls (motors, starters, solenoids, etc.) should be housed separately or at the farthest point when enclosed within the cabinet.

We recommend that the EZPLC has a minimum clear space of 2” on all sides.

2.3 Electrical Considerations

Understanding Electrical Noise,

Optical Isolation, and Shielding of Cables

This section will provide you with a very basic understanding of Electrical

Noise and how to keep it away from CPUs.

Industrial plants that have a number of generators of electrical noise are sometimes also referred to as Radio Frequency Interference or

RFI. Anytime an inductive load like a motor, motor starter, or solenoid is turned off, it generates a burst of excess energy that has to fl ow back to ground, just like electrical energy from a lightening storm has to fl ow back to Earth. Other sources are RF Welders or Radio Transmitters.

RFI is short bursts of electrical energy at very high frequencies.

Electronic controls use faster and faster CPUs today. These CPUs are also operating at 2.5V to 5VDC logic level power supply. RFI, if allowed to enter the CPU inside, is a killer of logic. A CPU under this environment loses its brain and behaves erratically. A smart industrialgrade CPU like the EZPLC’s Card Engine, when faced with RFI, halts its operation instead of giving false outputs.

Power Input

Transformer or

Choke Isolation

Chapter 2 - Installation

3. How to Keep RFI Isolated from CPUs

Optical Isolation

EZPLC

Logic Level inside Dotted Lines

CPU

Card

Engine

I/O

Module

EZPLC

Power

Supply

Filter

I/O

Module Motherboard at Logic

Level

2-5

Transformer or

Choke Isolation

Programming Device,

Operator Interface on

Network

Optical Isolation

Cabinets

Equipment cabinets usually incorporate one or two doors and/or hinged cabinet panels. In addition, sub-panels may be utilized on those electronic controls and electromechanical items that are mounted.

The goal here is to create a medium for mounting the equipment and ensure grounding of the control’s chassis to it. Relying on door hinges and swinging panels for a good metallic bond between hinged parts and the main body of the cabinet does not insure adequate grounding. That is why the use of ground straps is recommended.

RS232 Wiring Diagram

RS422/485 Wiring Diagram

RFI enters electronic controls in two ways:

• Radiated RFI

• Conducted RFI

For most practical purposes, electronic devices, unless sitting right next to a powerful RFI transmitter, will not be affected by noise because air space severely attenuates such interference. On the other hand, conducted RFI travels over conductive surfaces such as power supply wires, electrical wiring of fi eld devices, and worst of all; improper ground planes.

It is a common practice with PLCs to isolate the sensitive CPU of the PLC from RFI by providing Transformer or Choke Isolation on the Power Supply and optical isolation at the I/O side. EZPLC isolates the conducted RFI by both means, transformer/choke isolation as well as optical isolation for

I/O modules.

It is vital for the reliable operation of any electronic device to have any of its metallic surface well grounded to Earth. This not only provides for safe operation, it also will drain out any conducted RFI to Earth, away from the CPU’s signal ground. Obviously, the metal cabinet


Cabinet Door Grounding Straps

Cabinet Chassis Grounding

Star washers for proper grounding housing the EZPLC should also be well grounded. The following section will detail these procedures.

Power cables, I/O cables or wiring and communication cables should all be separate so that they do not couple the conducted RFI on any of these wires/cables. Communication cables such as Ethernet, DeviceNet and

Profi bus cables have their own standards for noise isolation which must be followed. Another path for RFI into the EZPLC is through its RS232 and

RS422/485 ports. The cables to these ports must be shielded properly as shown in the following diagrams.

Cabinet Grounding

Equipment cabinets usually incorporate one or two doors and/or hinged cabinet panels. In addition, sub-panels may be utilized on those electronic controls and electromechanical items that are mounted.

The goal is to create a medium for mounting the equipment and ensure grounding of the control’s chassis to it. Relying on door hinges and swinging panels for a good metallic bond between hinged parts and the main body of the cabinet does not insure adequate grounding. That is why the use of ground straps is recommended.

The equipment enclosures are generally either painted or anodized. It is imperative that the equipment chassis are grounded. Not only is this good safety practice, but it also helps noise immunity problems. Mounting of painted or anodized enclosures to like surfaces does not insure good metallic contact between the equipment chassis and cabinet.

The use of star washers when mounting the EZPLC, or other components, provides suffi cient grounding on the panel.

Cabinet Wiring

The wiring of the EZPLC to the “fi eld” outside the cabinet must be by design.

The wiring cannot be random in order to get the various points of the cabinet and the “fi eld” electrically connected.

Some general rules that apply in most situations:

• Provide a separate power source to electronic controls and keep this power buss away from any I/O power.

• The cabinet should be wired with a safety ground (the main safety

ground wire gauge is determined by the cabinet’s total current

consumption) and in accordance with all electrical code

requirements.

• Once the cabinet doors, stationary sub-panels and swing-out sub- panels have been “strapped” to the main cabinet, it is not necessary to run safety ground wires from the equipment chassis terminals to the main safety ground connection.

• The safety ground terminal of each component can, and should be, connected with the shortest wire possible, to the cabinet or sub-panel

frame.

• Plan the wiring routing. Keep all switched power in separate ducts and if there is AC and DC power being switched, keep the wiring of each branch separate from all wires and cables carrying low level signals.

• Keep all three phase power outside of the cabinet, but if it becomes necessary, keep the runs as short as possible and maintain the maximum possible distance between the three phase buss and all other

wiring.


AC/DC Transient Protection

Recommended AC Inductive Transient Protection

CAUTION! MOV should be

2 times the load voltage and have suffi cient energy rating corresponding to the load.

AC Output Module

CAUTION! D1 should have at least 100 PIV and 3 Amp current capacity.

Recommended DC Sinking Transient Protection

CAUTION! EZPLC’s

D C o u t p u t s h a v e a built-in fl yback diode to absorb an inductive kick.

For this Diode to work effectively, the 24VDC power source powering the inductive load must be connected to the EZIO module.

Use these recommended external suppressors for improved safety.

DC Output Module

• Primary power leads to the control equipment (Base power terminals) should be made with a two wire twisted cable with approximately 12 turns per foot. The length of these cables should be kept to a minimum and to the greatest extent possible such cable runs should be kept separate from other wiring.

• In the case of AC powered equipment, the primary power should be provided separately from the power source used for I/O control.

AC Line Noise

The AC power available in house outlets and at sub-stations powering industrial and commercial applications is generally generated at a power station miles away from the point of usage.

The power is “noise” free at the time it is being generated, and meets all specifi cations for amplitude, frequency, harmonic distortion and others.


However, the same specifi cations cannot be guaranteed at the point of usage, due to the disruptive factors associated with the transmission from generator to consumer.

While the generated power output starts its journey “clean,” and free of noise, it is “polluted” by radio and TV frequencies, spikes from reactive kickbacks due to switching heavy inductive and capacitive loads in transmission lines, and from other interference.

As a result, critical and sophisticated electronic controls may malfunction; false triggering, user program loss and/or modifi cation may occur and even catastrophic failure.

In view of the problems associated with AC power, it is strongly recommended the source, transmission and fi nal end use be given stringent consideration before any commitment to supply the system is given. Some typical problems in power line usage are:

• Blackouts: This is the total loss of power. Generally, they are easy to detect and if a situation arises where they cannot be tolerated then an un-interrupted power supply (UPS)

• Brownouts: This occurs when there is a reduction in line voltage amplitude. If this reduction falls within operating limits,

no adverse effects will be experienced. However, if they are frequent and severe, a UPS system should be

considered.

• Voltage

Fluctuations: These are amplitude variations (rapid or slow) and can occur above or below the specifi ed limits. Over-voltage conditions may damage equipment if the duration of the voltage condition is lengthy. It may cause disruptions, data loss, and

• Noise

Spikes: Noise spikes and other unwanted signals superimposed on the AC line voltage waveform are the most common problems associated with the distribution of the power from its grid system. The amplitude of these signals can be from several hundred to a few thousand volts and the pulse width from about one to 200 microseconds. Because of their short duration and random occurrences, these harmful signals

Dealing with AC Line Noise

The best option to effectively eliminate or greatly reduce voltage fl uctuations, spikes and line noise is through the use of isolation, constant voltage or power line conditioner transformer.

Isolation transformers are passive devices that do not have DC paths between the circuits they isolate. The transformer provides attenuation to spikes and common mode noise, but has virtually no effect on transverse mode noise and does not provide protection for voltage fl uctuations.

Constant voltage transformers are static Ferro-resonant transformers that can accept fl uctuating AC voltage input (within a specifi ed range)


Power connection

DC AC

L1

L2 and maintain a constant voltage output. The transformers provide good attenuation to transverse mode type noise, however, are ineffective for attenuation of common mode type signals.

Power line conditioning transformers provide good line regulation and are effective in providing attenuation to both common and transverse mode types of noise.

All of the mentioned transformer types are available by various manufacturers and they come in different varieties of operating voltages, power ratings, and frequencies.

CAUTION! Do not apply

AC power to DC models.

Do not apply 220VAC to AC models.

CAUTION! Keep the signal

GND for CPU Power and I/O

Power isolated.

AC Power Distribution

NOTE: Industrial Power

Supplies today are relatively inexpensive. Any good industrial DC Power Source has an

EMI fi lter built-in. An I/O DC Power

Supply does not have to be that well regulated on the other hand.

DC Powered EZPLC

System

If you are using 24VDC for DC Power for the EZPLC, we recommend that the power for the CPU (Card Engine) be a separate Power Supply and the power source for DC Loads be a DC

Load supply.

1” max

Ferrite

Cylinder

Power Terminals

Power Cable

The Power Cable Ferrite Core is a solid ferrite cylinder. The Power Cable should pass once through the core, be looped around and pass through a second time. Pull the excess cable so that it rests snugly against the outside of the core.


2.4 Sourcing (P type) and Sinking (N type) I/O

You will come across these two terms quite often in the world of automation controls. This section will give you a short explanation and a simple way to remember the terminology.

Source (P type) Sources Voltage to the receiver

Source (N type) Sinks current through the load into GND

NOTE: A sourcing output sources/supplies positive voltage to a load.

Sources/Supplies

Positive Voltage to Load

(10-28 VDC)

DC OUTPUT [SOURCE]

Sources/Supplies

Positive Voltage to Input

NOTE: A sourcing input expects positive voltage for it to activate.


NOTE: A sinking output sinks/receives current from a load.

DC OUTPUT [SINK]

Sinks/

Receives

Current through the Load

(10-28 VDC)

NOTE: A sinking input sends/sinks current to an external switch/output.

Sinks

Current to

Field Output


2.5 EZPLC Mounting

Mounting Dimensions

You need to know the dimensions of the EZPLC before mounting. The diagrams on the following pages provide exact Base dimensions. The dimensions here represent the EZPLC bases with I/O modules installed on them. However, it should be noted that EZPLC offers fl exibility to design your system based on your specifi c I/O requirements. So EZIO modules have to be purchased separately. EZIO has a snap-on design so that the

I/O modules can be installed on the Base easily.

There is no limitation on I/O module location, except:

1. The bottom left module cannot be AC Output or Relay module.

2. Analog input and output combination module can be confi gured only in the fi rst 4 slots.

3. All Analog or Specialty modules can be confi gured only in the fi rst

Use 4/6 screws with STAR washers to secure the unit to the mounting surface. Dimensions are provided in inches and millimeters, mm appear in brackets [ ].

EZPLC With 4 Slots per base, 32 I/O Max

Models:

EZPLC-A-32

EZPLC-A-32-E

EZPLC-D-32

EZPLC-D-32-E

Models:

EZPLC-A-48

EZPLC-A-48-E

EZPLC-D-48

EZPLC-D-48-E

EZPLC with 6 Slots per base, 48 I/O Max



Models:

EZPLC-A-64

EZPLC-A-64-E

EZPLC-D-64

EZPLC-D-64-E


Models:

EZPLC-A-96

EZPLC-A-96-E

EZPLC-D-96

EZPLC-D-96-E

CAUTION! The M2 slot cannot be used for any AC or Relay output module.

Also, modules with both

Analog inputs and outputs can be used only on slots M1 through M4 and Analog and Counter modules in general must be used from M1 through M10.

2.6 EZIO Modules Positioning

Slots Numbering System

As discussed earlier there are 4 bases you can choose from: 4 slots, 6 slots,

8 slots and 12 slots, that can support up to a maximum of 32, 48, 64 and

96 I/O points respectively. Use the following conventions to identify the slot numbers on the bases.

You can confi gure the positioning of the I/O modules on the Base by clicking on the Confi gure I/O button. The picture above shows the I/O module positioning convention employed in EZPLC. Following are the guidelines/ recommendations for installing I/O modules on an EZPLC base. We have shown and described the 12-slots (capable of 96 I/O points MAX) base here; however the module numbering convention as well as the positioning guidelines remain the same for smaller bases.


EZ I/O Modules

Module Positioning Restrictions

Recommendations for

Positioning of Modules

DC Modules

EZIO-8DCI

EZIO-8DCOP

EZIO-8DCON

EZIO-8HSDCI

EZIO-4DCI4DCON

EZIO-4DCI4DCIF

EZIO-4DCI4DCOP

8 point DC Inputs (sink/source)

8 point DC (source) Outputs

8 point DC (sink) Outputs

8 point High Speed DC Inputs (sink/source)

4 point DC (sink/source) Inputs; 4 point DC (sink) outputs

4 point DC (sink/source) Inputs; 4 point High Speed DC (sink/source) Inputs

4 point DC (Sink/Source) Inputs; 4 point DC (source) outputs

AC Modules

EZIO-8ACI

EZIO-8ACO

EZIO-4ACI4DCOP

EZIO-4DCI4ACO

Analog Modules

EZIO-8ANIV

8 point AC Inputs

8 point AC Outputs

EZIO-4ACI4ACO

AC/DC Combo Modules

4 point AC Inputs; 4 point AC Outputs

EZIO-4DCOP4ACO 4 point DC (source) Outputs; 4 point AC outputs

4 point AC Inputs; 4 point DC (source) outputs

4 point DC (sink/source) Inputs; 4 point AC Outputs

EZIO-8ANIC

EZIO-4ANI4ANOV

EZIO-4ANI4ANOC

8 channel Analog Input module (Voltage)

8 channel Analog Input module (Current)

4 Channel Analog Inputs; 4 Channel Analog Outputs


Relay Modules

EZIO-4IORLO

EZIO-4ACI4RLO

EZIO-4DCOP4RLO

Specialty Modules

EZIO-4THI

EZIO-4HSCM1

EZIO-4HSCM2

4 point Relay Outputs

4 point AC Inputs; 4 point Relay Outputs

4 point DC (sink/source) Outputs; 4 point Relay Outputs

4 Channel thermocouple input module

High Speed 24-Bit Counter module


Any Slot

Any Slot Except M2

(will not fi t over battery)

Any Slot

Any Slot Between M1 and M10 Except M2

Any Slot Except M2

Any Slot Except M2

Any Slot Except M2

Any Slot Except M2






3 Modules Max per Base


EZIO Module Dimensions

STEP 1

2.7 EZIO Mounting and Wiring

EZIO Installation Overview

EZIO modules are designed with one thing in mind - modularity! Any base of EZPLC can be fi tted with each and every EZIO module. All EZ Family

PLCs are designed to handle any combination of EZIO modules without any need for power budgeting. Most EZIO modules consume only 20-40 mA current at 3.3V.

Mounting I/O Modules

EZIO modules have a snap-on design to facilitate easy installation and removal from the base slots. The I/O modules have two clips and a Molex connector, which snap into EZPLC Base.

STEP 2

STEP 1 - Hold the module in the thumb and index fi nger so that your fi ngertips are on the clips.

STEP 2 - Snap the module on the board so that clips are placed on the open mounting slots. Make sure that the

Molex connector is aligned to the female counterpart on the base. Push the module gently from the top to insert it completely until you hear a clicking sound.

Molex connector

Mounting slot

Wiring EZIO Modules

As shown in the picture, simply insert the wire and screw to tighten. You can wire up to ONE 14 AWG wire, TWO 18 AWG wires, or FOUR 22 AWG wires in every terminal. You will need a 2.5mm blade screwdriver (P/N EZIO-

SCDRV) to work with the EZIO terminal blocks and wiring.

Routing EZIO Wiring

EZIO modules have wiring trays for proper routing of fi eld wires.


Number of Wires

Allowed in Each Terminal

1 14 AWG

2 18 AWG

4 22 AWG

Wiring Capabilities

UL rated at 300 volts, 10 amps 14 AWG

Discrete I/O Module Status Indicators

The discrete I/O modules have LED status indicators to provide visual indication of the input points activity.

Removable Terminal Blocks

EZIO eliminates the need for rewiring your terminal block anytime you need to swap a module. Since these modules are built to withstand industrial environments, terminal blocks fi t very snugly on the module. Slip the edge of the screwdriver under the terminal block and lift to pop it off.

Removing I/O Modules

• Hold the module in the thumb and index fi nger so that your fi ngertips are on the clips.

• Apply inward pressure on the two clips with your fi ngers to release the module from the mounting slots on the base.

• Pull the module out.

Module Specifi cations

Number of Inputs 8 (sink/source)

Input Voltage Range

Peak Voltage

Input Current

10-28 VDC

40 VDC

1.92 mA @ 12 VDC

4.0 mA @ 24 VDC

Maximum Input Current

Input Impedance

ON Voltage Level

OFF Voltage Level

Min. ON Current

Min. OFF Current

OFF to ON Response

5 mA @ 28 VDC

5.6k @ 10-28 VDC

> 10 VDC

< 2 VDC

1.5 mA

0.2 mA

2-4 ms, typical 3 ms

ON to OFF Response

Status Indicators

Commons

Fuse


Red LED for each input

2 points

No Fuse

Base Power Required (3.3V) Typical 15mA (all inputs on)

Optical Isolation 2500 Volt

Wires

1 of 14 AWG, 2 of 18 AWG,

4 of 22 AWG


2.8 EZI/O Modules

EZIO-8DCI

8 pt. 24VDC Input Module

Pinout Information

6

7

4

5

Pin No.

EZIO-8DCI

1 Input(1)

2

3

Input(2)

Input(3)

Input(4)

COM

Input(5)

Input(6)

10

11

8

9

Input(7)

Input(8)

COM

Not Connected

2-17


EZIO-8DCOP

8 pt. 24VDC Output Module (Source)


Number of Outputs 8 sourcing

Peak Voltage

Maximum Steady State

Output Current

50.0 VDC

0.5A per output,

1.0A max per module @ 50°C

Maximum Leakage Current 100µA @ 50 VDC @ 50°C

ON Voltage Drop 2 VDC @ 0.5A

Maximum Inrush Current


0.8A for 10ms

< 2µs


Short Circuit Protection

<10µs

Status Indicators Red LED for each output

+V Terminals & Commons One V + , 2 Common

1 Amp per module, turns off outputs upon short circuit detection

Base Power Required (3.3V) 40mA, all outputs on


Wires


4 of 22 AWG


Pin No.

EZIO-8DCOP

6

7

4

5

1

2

3

10

11

8

9

Output(1)

Output(2)

Output(3)

Output(4)

GND

Output(5)

Output(6)

Output(7)

Output(8)

GND

Customer_Supply( +VS )

(10-28 VDC)

DC OUTPUT [SOURCE]


EZIO-8DCON

8 pt. 24VDC Output Sinking Module


Number of Outputs

Peak Voltage

8 sinking

50.0 VDC



0.5A per output,


Maximum Leakage Current 100µA @ 50 VDC @ 50°C

ON Voltage Drop 1.3 VDC @ 0.5A



1.0A for 10ms

< 2µs



<10µs

Red LED for each output

+V Terminals & Commons One V + , 2 Common


1.4 Amp per module, turns off outputs upon short circuit detection



Wires


4 of 22 AWG

9

10

11

7

8

5

6


Pin No.

EZIO-8DCON

1 Output(1)

2

3

4

Output(2)

Output(3)

Output(4)

GND

Output(5)

Output(6)

Output(7)

Output(8)

GND


(10-28 VDC)

DC OUTPUT [SINK]


EZIO-8HSDCI

8 pt. 24VDC High Speed Input Module

Number of Inputs


Peak Voltage

Input Current








Commons

Fuse

Wires




Base Power Required (3.3V)

Optical Isolation

8 (sink/source)

10-28 VDC

40 VDC

1.92 mA @ 12 VDC

4.0 mA @ 24 VDC

5 mA @ 28 VDC

5.6k @ 10-28 VDC

> 10 VDC

< 2 VDC

1.5 mA

0.2 mA

0.2-0.4 ms, typical 0.3 ms



2 points

No Fuse

Typical 15 mA (all inputs on)

2500 Volt

1 of 14 AWG, 2 of 18

AWG, 4 of 22 AWG


Pin No.

EZIO-8HSDCI

7

8

9

10

11

4

5

6

1

2

3

Input(1)

Input(2)

Input(3)

Input(4)

COM

Input(5)

Input(6)

Input(7)

Input(8)

COM

Not Connected


EZIO-4DCI4DCON

8 pt. 24VDC Output Sinking Module


DC Power

Supply Specs

Voltage Range

DC Input Specs

DC Output

Specs



Peak Voltage

Input Current










4 (sink/source)

10-28 VDC

40 VDC

1.92 mA @ 12 VDC

4.0 mA @ 24 VDC

5 mA @ 28 VDC

5.6k @ 10-28 VDC

> 10 VDC

< 2 VDC

1.5 mA

0.2 mA




Commons

Fuse



Wires


Peak Voltage



Maximum Leakage Current

1 point

No Fuse

Typical 7.5 mA (all inputs on)

2500 Volt

1 of 14 AWG, 2 of 18

AWG, 4 of 22 AWG

4 (sourcing)

50.0 VDC

0.5A per output,

1.0A max per module

@ 50°C

100µA @ 50 VDC @

50°C

ON Voltage Drop





2 VDC @ 0.5A

0.8A for 10ms

< 2µs

<10µs


One V + , 1 Common +V Terminals & Commons


Wires




1 of 14 AWG, 2 of 18

AWG,

4 of 22 AWG


Pin No.

EZIO-4DCI4DCON

5

6

7

8

1

2

3

4

9

10

11

Input(1)

Input(2)

Input(3)

Input(4)

COM

Output(1)

Output(2)

Output(3)

Output(4)

GND


(10-28 VDC)

2-21


EZIO-4DCI4DCIF

4 pt. 24VDC In/4 pt. 24VDC Fast

Input Module with Interrupt


DC Power

Supply Specs

Voltage Range


(Standard)


(Fast)


Wires

2500 Volt

1 of 14 AWG, 2 of 18 AWG, 4 of 22 AWG

4 (sink/source) Number of Inputs


Peak Voltage

Input Current

10-28 VDC

40 VDC

1.92 mA @ 12 VDC

4.0 mA @ 24 VDC

5 mA @ 28 VDC Maximum Input Current








5.6k @ 10-28 VDC

> 10 VDC

< 2 VDC

1.5 mA

0.2 mA




Commons


1 point

Base Power Required (3.3V) Typical 3.5 mA (all inputs on)



Peak Voltage

Input Current

4 (sink/source)

10-28 VDC

40 VDC

1.92 mA @ 12 VDC

4.0 mA @ 24 VDC

5 mA @ 28 VDC Maximum Input Current








5.6k @ 10-28 VDC

> 10 VDC

< 2 VDC

1.5 mA

0.2 mA


For Inputs 5,6 and 7


For Inputs 5,6 and 7

Interrupt


Commons

Fuse

Low pass fi lter of 20µs,

60µs typical response time from input interrupt, 1 rung of processing and output activation, For Input # 8


1 point

No Fuse

Base Power Required (3.3V) Typical 3.5 mA (all inputs on)


6

7

4

5

Pin No.

EZIO-4DCI4DCIF

1 Input(1)

2

3

Input(2)

Input(3)

Input(4)

GND

Fast Input(5)

Fast Input(6)

10

11

8

9

Fast Input(7)

Fast Input(8) - Interrupt

GND

Not Connected


EZIO-4DCI4DCOP

4 pt. 24VDC In/4 pt. 24VDC Out Module (Source)


DC Power

Supply Specs

Voltage Range


DC Output

Specs



Peak Voltage

Input Current









4 (sink/source)

10-28 VDC

40 VDC

1.92 mA @ 12 VDC

4.0 mA @ 24 VDC

5 mA @ 28 VDC

5.6k @ 10-28 VDC

> 10 VDC

< 2 VDC

1.5 mA

0.2 mA



Commons

Fuse





1 point

No Fuse

Typical 8 mA (all inputs on)

2500 Volt

Wires


Peak Voltage

1 of 14 AWG, 2 of 18

AWG, 4 of 22 AWG

4 sinking

50.0 VDC









0.5A per output,

1.4A max per module

@ 50°C

100µA @ 50 VDC

@ 50°C

1.5 VDC @ 0.5A

1.0A for 10ms

< 2µs

<10µs




Wires

1.4 Amp per module, turns off outputs upon short circuit detection



1 of 14 AWG, 2 of 18

AWG, 4 of 22 AWG


Pin No.

EZIO-4DCI4DCOP

7

8

5

6

3

4

1

2

9

10

11

Input(1)

Input(2)

Input(3)

Input(4)

GND

Output(1)

Output(2)

Output(3)

Output(4)

GND


(10-28 VDC)


EZIO-8ACI

8 pt. 110VAC Input Module


Number of Inputs 8

Input Voltage Range 70-132 VAC

AC Frequency

Peak Voltage

Input Current








47-63 Hz

180 Volt

0.5mA @ 110 VAC

0.6mA @ 132 VAC

200K

70 VAC

40 VAC

< 10ms

< 10ms


Commons

Fuse

Wires

2 Commons

No fuse

Base Power Required (3.3V) 20mA for all 8 on


1 of 14 AWG, 2 of 18

AWG, 4 of 22 AWG


Pin No.

EZIO-8ACI

7

8

5

6

3

4

1

2

9

10

11

Input(1)

Input(2)

Input(3)

Input(4)

AC_Common

Input(5)

Input(6)

Input(7)

Input(8)

AC_Common

Not Connected

Internal

External


EZIO-8ACO

8 pt. 110VAC Output Module


Number of Output Points 8

Number of Commons 2

Output Voltage Range

Peak Voltage


Maximum Current

20-132 VAC

180 Volt

1.2 V @ 1A

1.2 A @ 25°C, 0.8A @

50°C for each output

Maximum Leakage Current 1mA @ 132 VAC

Maximum Inrush Current 38Amps for 16.6ms

Minimum Load



15mA max 1/2 cycle max 1/2 cycle

Fuse No fuse



Wires

2500 Volt

1 of 14 AWG, 2 of 18

AWG, 4 of 22 AWG


Pin No.

EZIO-8ACO

5

6

7

8

3

4

1

2

9

10

11

Output(1)

Output(2)

Output(3)

Output(4)

AC_Common

Output(5)

Output(6)

Output(7)

Output(8)

AC_Common

Not Connected

Internal

External


EZIO-4ACI4ACO

4 pt. 110VAC In, 4 pt. 110VAC Out Module


AC Power

Supply Specs

Voltage Range

AC Input Specs

AC Output

Specs



AC Frequency

Peak Voltage

4

70-132 VAC

47-63 Hz

180 Volt

Input Current








Commons

Fuse

0.5mA @ 110 VAC

0.6mA @ 132 VAC

200K

70 VAC

40 VAC

< 10ms

< 10ms


1 Common

No fuse



Wires

1 of 14 AWG, 2 of 18

AWG, 4 of 22 AWG

Number of Output Points

Number of Commons


Peak Voltage


4

1

20-132 VAC

180 Volt


1.2 V @ 1A

1.2 A @ 25°C, 0.8A @




Minimum Load



Fuse


No fuse



Wires

1 of 14 AWG, 2 of 18

AWG, 4 of 22 AWG

External

External


Pin No.

EZIO-4ACI4ACO

5

6

7

8

3

4

1

2

9

10

11

Input(1)

Input(2)

Input(3)

Input(4)

AC_Common

Output(1)

Output(2)

Output(3)

Output(4)

AC_Common

Not Connected

Internal

Internal


EZIO-4DCOP4ACO

4 pt. 24VDC Out (Source), 4 pt. 110AC Out Module

AC/DC Power

Supply Specs

DC Output

Specs

AC Output

Specs


Voltage Range


Peak Voltage




4 (sourcing)

50.0 VDC

0.5A per output,

1.0A max per module

@ 50°C

100µA @ 50 VDC

@ 50°C

2 VDC @ 0.5A ON Voltage Drop




0.8A for 10ms

< 2µs


<10µs





Base Power Required (3.3V) 20mA, for all 4 on


Wires

2500 Volt

1 of 14 AWG, 2 of 18

AWG, 4 of 22 AWG




Peak Voltage



4

1

20-132 VAC

180 Volt

1.2 V @ 1A

1.2 A @ 25°C, 0.8A @




Minimum Load




Fuse No fuse



Wires

2500 Volt

1 of 14 AWG, 2 of 18

AWG, 4 of 22 AWG

External


Pin No.

EZIO-4DCOP4ACO

9

10

7

8

11

3

4

5

6

1

2

AC Output(1)

AC Output(2)

AC Output(3)

AC Output(4)

AC_Common

DC Output(5)

DC Output(6)

DC Output(7)

DC Output(8)

GND


Internal

(10-28 VDC)


EZIO-4ACI4DCOP

4 pt. 110VAC In/ 4 pt. 24VDC Out Module (Source)


AC/DC Power

Supply Specs

Voltage Range

AC Input Specs

DC Output

Specs



AC Frequency

Peak Voltage

Input Current








4

70-132 VAC

47-63 Hz

180 Volt

0.5mA @ 110 VAC

0.6mA @ 132 VAC

200K

70 VAC

40 VAC

< 10ms

< 10ms


Commons

Fuse

Wires

1 Common

No fuse



1 of 14 AWG, 2 of 18

AWG, 4 of 22 AWG


Peak Voltage

4 (sourcing)

50.0 VDC





0.5A per output,

1.0A max per module

@ 50°C

100µA @ 50 VDC

@ 50°C

2 VDC @ 0.5A





0.8A for 10ms

< 2µs

<10µs





Base Power Required (3.3V) 24mA, for all 4 on


Wires

Wires

1 of 14 AWG, 2 of 18

AWG, 4 of 22 AWG

1 of 14 AWG, 2 of 18

AWG, 4 of 22 AWG


Pin No.

EZIO-4ACI4DCOP

5

6

7

8

3

4

1

2

9

10

11

Input(1)

Input(2)

Input(3)

Input(4)

AC_Common

Output(1)

Output(2)

Output(3)

Output(4)

GND


External

Internal

AC (Input)

(10-28 VDC)

DC Output (Source)


EZIO-4DCI4ACO

4 pt. 24VDC In/ 4 pt. 110VAC Out Module


AC/DC Power

Supply Specs

Voltage Range


AC Output

Specs



Peak Voltage

Input Current










Commons

Fuse



Wires




Peak Voltage



4 (sink/source)

10-28 VDC

40 VDC

1.92 mA @ 12 VDC

4.0 mA @ 24 VDC

5 mA @ 28 VDC

5.6k @ 10-28 VDC

> 10 VDC

< 2 VDC

1.5 mA

0.2 mA




1 point

No Fuse

Typical 7.5 mA (all inputs on)

2500 Volt

4

1

1 of 14 AWG, 2 of 18

AWG, 4 of 22 AWG

20-132 VAC

180 Volt

1.2 V @ 1A

1.2 A @ 25°C, 0.8A @




Minimum Load 15mA



Fuse No fuse


Optical Isolation max 1/2 cycle max 1/2 cycle

Wires

2500 Volt

1 of 14 AWG, 2 of 18

AWG, 4 of 22 AWG


Pin No.

EZIO-4DCI4ACO

5

6

7

1

2

3

4

10

11

8

9

Input(1)

Input(2)

Input(3)

Input(4)

GND

Output(1)

Output(2)

Output(3)

Output(4)

AC_Common

Not Connected

External

Internal


EZIO-4RLO

4 pt. Relay Out Module w/built-in Electromagnetic shield




Output Type

4

5-180 VDC or

20-132 VAC

Relay 1 Form A

(SPST)

Output Terminals

Consumed

Peak Voltage

AC Frequency

8

180 VDC/200 VAC

47-63 Hz

Maximum Current (resist.) 1A/point


0.5mA @ 130 VAC

@ 60Hz

Maximum Switching

Current

0.5A

Electromagnetic Shield

Dielectric Strength

2 pF between contact and shield

250V between contacts, 1500V between contacts and shield



≤1ms (typical)

≤1ms (typical)


Contacts

Red LEDs

4 isolated

Base Power Required (3.3V) 50mA

External


Pin No.

EZIO-4RLO

6

7

4

5

1

2

3

10

11

8

9

Output(1)_Normally open

Output(1)_COM


Output(2)_COM

Not Connected

Not Connected


Output(3)_COM

Not Connected


Output(4)_COM

Internal

(20-132 VAC)

(5-180 VDC)


EZIO-4ACI4RLO

4 pt. 110 AC In/4 pt. Relay Out Module w/built-in Electromagnetic shield

AC Input

Specs

Relay

Output

Specs


Number of Inputs 4


AC Frequency

Peak Voltage

Input Current





70-132 VAC

47-63 Hz

180 Volt

0.5mA @ 110 VAC

0.6mA @ 132 VAC

200K

70 VAC

40 VAC




< 10ms

< 10ms


Commons

Fuse

1 Common

No fuse



Wires



Output Type

2500 Volt

1 of 14 AWG, 2 of 18

AWG, 4 of 22 AWG

4

5-180 VDC or

20-132 VAC

Relay 1 Form A

(SPST)


Consumed

Peak Voltage

AC Frequency

Maximum Current (resist.)


5

180 VDC/200 VAC

47-63 Hz

1A/point

0.5mA @ 130 VAC

@ 60Hz

1.5 V @ 1 Amp ON Voltage Drop


Current

0.5A







≤1ms (typical)

≤1ms (typical)


Commons

Red LEDs

1



Pin No.

EZIO-4ACI4RLO

1 Input(1)

5

6

7

2

3

4

10

11

8

9

Input(2)

Input(3)

Input(4)

Customer_COM (GND)

Output(1)

Output(2)

Output(3)

Output(4)

Customer_COM (GND)

Not Connected

External Internal

2-31


DC

Input

Specs

Relay

Output

Specs




Peak Voltage

Input Current










Commons

Fuse



Wires



Output Type

2500 Volt

1 of 14 AWG, 2 of 18

AWG, 4 of 22 AWG

4

5-180 VDC or

20-132 VAC

Relay 1 Form A

(SPST)


Consumed

Peak Voltage

AC Frequency

Maximum Current (resist.)


5

180 VDC/200 VAC

47-63 Hz

1A/point

0.5mA @ 130 VAC

@ 60Hz

1.5 V @ 1 Amp ON Voltage Drop


Current

0.5A





≤1ms (typical) OFF to ON Response



≤1ms (typical)

Red LEDs

Commons 1


4 (sink/source)

10-28 VDC

40 VDC

1.92 mA @ 12 VDC

4.0 mA @ 24 VDC

5 mA @ 28 VDC

5.6k @ 10-28 VDC

> 10 VDC

< 2 VDC

1.5 mA

0.2 mA




2 points

No Fuse

Typical 7.5mA (all inputs on)

EZIO-4DCIP4RLO

4 pt. 24VDC In/4 pt. Relay Out Module w/built-in Electromagnetic shield

External


Pin No.

EZIO-4DCIP4RLO

7

8

9

5

6

10

11

3

4

1

2

Input(1)

Input(2)

Input(3)

Input(4)

Customer_COM (GND)

Output(1)

Output(2)

Output(3)

Output(4)

Customer_COM (GND)

Not Connected

Internal


EZIO-8ANIV

8 pt. Analog In Module (Voltage)


Number of Channels

Input Range

Resolution

Step Response

Crosstalk


Absolute Max Ratings

Converter Type

8 single ended

0-5, 0-10V DIP switch selectable

12 bit (4 in 4 or 6)

200µs to 95% of FS

1/2 count max, -80db

>20KΩ

± 15V successive approximation

Linearity Error (end to end) ± 2 count

Input Stability ± 2 count

Gain Error

Offset Calibration Error

± 2 counts

± 5 counts

Max Inaccuracy

± 0.2% at 25°C,

± 0.4% at 0-60°C

Accuracy vs. Temperature ± 50 ppm/°C typical

Internal


Pin No.

EZIO-8ANIV

7

8

5

6

3

4

1

2

9

10

11

Input(1)

Input(2)

Input(3)

Input(4)

Customer_COM ( Analog GND)

Input(5)

Input(6)

Input(7)

Input(8)


Not Connected

External


EZIO-8ANIC

8 pt. Analog In Module (Current)



Input Range

Resolution

Step Response

Crosstalk




8 Single Ended

0-20mA or 4-10 mA

DIP switch selectable

12 bit (1 in 4 or 6)

200µs for 95% FS


62.5Ω ± 0.1%

-30mA to 30mA

Successive

Approximation

Linearity Error (end to end) ± 2 counts


Full-scale Calibration Error ± 10 counts @ 20mA



± 5 counts

± 0.3% @ 25°C,

± 0.6% @ 60°C

Accuracy vs. Temperature ± 50 ppm/°C typical

Recommended Fuse

.032 Amp, series 217 fast acting

Internal


Pin No.

EZIO-8ANIC

5

6

7

8

3

4

1

2

9

10

11

Input(1)

Input(2)

Input(3)

Input(4)


Input(5)

Input(6)

Input(7)

Input(8)


Not Connected

External


EZIO-4ANI4ANOV

4 pt. Analog In/4 pt. Analog Out Module (Voltage)

Analog

Voltage

Input

Specs

Analog

Voltage

Output

Specs



Input Range

Resolution

Step Response

Crosstalk




4 single ended

0-5, 0-10V DIP switch selectable

12 bit (4 in 4 or 6)

200µs to 95% of FS


>20KΩ

± 15V successive approximation



Gain Error



± 2 counts

± 5 counts

± 0.2% at 25°C,

± 0.4% at 0-60°C

Accuracy vs. Temperature


Output Range

± 50 ppm/°C typical

4 single ended (1 common)

0-5 VDC, 0-10 VDC

(DIP switch selectable)

12 bits (1 in 4096) Resolution

Conversion Setting Time

Crosstalk

Peak Output Voltage

Offset Error

100 µs for FS


± 18 VDC

± 0.15% of range

Gain Error ± 0.3% of range


Output Stability ± 2 counts

Load Impedance

Load Capacitance


2k Ω min.

.01 microF max

± 50 ppm/C typical

Internal


Pin No.

EZIO-4ANI4ANOV

1 Output(1)

10

11

8

9

4

5

6

7

2

3

Output(2)

Output(3)

Output(4)


Input(1)

Input(2)

Input(3)

Input(4)


Not Connected

External

2-35


EZIO-4ANI4ANOC

4 pt. Analog In/4 pt. Analog Out Module (Current)


Number of Channels 4 Single Ended

Input Range

Resolution

Step Response

Crosstalk



0-20mA or 4-10 mA

DIP switch selectable

12 bit (1 in 4 or 6)

1ms for 95% FS


62.5Ω ± 0.1%

-30mA to 30mA

AC Input

Specs


Successive

Approximation



Full-scale Calibration Error ± 10 counts @ 20mA

Offset Calibration Error ± 5 counts



± 0.3% @ 25°C,

± 0.6% @ 60°C

± 50 ppm/°C typical

Recommended Fuse


.032 Amp, series 217 fast acting

4 single ended

Output Range

AC Output

Specs

Output Type

Resolution

Max. Loop Voltage

Load/loop Power Supply

0-20mA, 4-20mA

(DIP switch selectable)

Current Sourcing

12 bit (1 in 4 or 6)

30 VDC

0-300Ω/18-30 VDC


Conversion Setting Time 100µs for FS

Full-scale Calibration Error ± 12 counts

Offset Calibration Error ± 6 counts

Max. Full-scale Inaccuracy

(all errors included)

± 0.3%

Internal


Pin No.

EZIO-4ANI4ANOC

9

10

11

7

8

3

4

5

6

1

2

Output(1)

Output(2)

Output(3)

Output(4)


Input(1)

Input(2)

Input(3)

Input(4)


Not Connected

External


EZIO-4THI

Thermocouple Input Module

2-37


Number of Channels 4, differential

Common Mode Range -1.5 VDC to +4.0 VDC

Common Mode

Rejection


100dB min. @ VDC

50/60Hz

5MΩ

Absolute Maximum

Ratings

Fault-protected inputs to

±50 VDC

Accuracy vs.

Temperature

± 15ppm/°C max.

0-1.25V ±35 ppm/°C max.

(including max. offset change)

4 channels per scan PLC Update Rate

Base Power

Required

10mA @ 3.3 VDC supplied by base

Operating Temperature 32° to 140°F (0° to 60°C)

Storage Temperature -4° to 158°F (-20° to 70°C)

Relative Humidity

Environmental Air

Vibration

Shock

Noise Immunity

Replacement

Terminal Block

5 to 95% (non-condensing)

No corrosive gases permitted

MIL STD 810C 514.2

MIL STD 810C 516.2

NEMA ICS3-304

EZIO-TERM11CJC

(comes with CJC)


Pin No.

4 Thermocouple Input

1 CHAN1 + ( Input)

9

10

7

8

4

5

2

3

6

11

CHAN1 - ( Input)

CHAN2 + ( Input)

CHAN2 - ( Input)

CHAN3 + ( Input)

CHAN3 - ( Input)

CHAN4 + ( Input)

CHAN4 - ( Input)

+ 5 VDC

Vout ( Temp. Sensor)

Analog GND

Thermocouple Specifi cations

Input Ranges in C

Type J -40 to 340°C

Type K -80 to 450°C

Type S 25 to 720°C

Type T -180 to 330°C

Type J,K,T ± 0.1°C; Type S ± 1°C Display Resolution

Cold Junction

Compensation

Conversion Time

Automatic

Warm-Up Time

1ms per channel

30 minutes typically

± 1°C repeatability

Linearity Error

(End to End)

± 1°C max. ± 0.5°C typical

Maximum Inaccuracy ± 3°C (excluding thermocouple error)


High Speed Counter Modules with PLS Outputs

Feature

Module Type

Maximum Input

Frequency

Minimum Pulse

Width

Resource Options

Counter Range

Module Specifi cations

EZIO-HSCM1 (dual) EZIO-HSCM2 (single)

Intelligent High Speed

Dual Counter Module

100KHz after 1X, 2X or 4X

Multiplication

Intelligent High Speed

Single Counter Module

60KHz after 1X, 2X or 4X

Multiplication

5 µs

Preset Modes

Reset Modes/Input

Inhibit Input

1X, 2X, or 4X Quadrature, Up or Down Counter, Reset

16 million (24 bits)

1. This mode will preset the counter to the preset value while preset is held high. While the preset signal is high, no new count signals will be counted.

2. This mode will create an interrupt on the rising edge of the reset signal to set the counter to the preset value.

3. This mode will create an interrupt on the falling edge of the preset signal to set the counter to the preset value.

4. This mode will create a preset pulse every time that there is a rising edge of signal A and the preset signal is high.

None

None

Same as Preset except the reset input sets the counter value to zero

Inhibits the counter from counting when high

PLS Output Specifi cations

Feature

EZIO-HSCM1

(dual counter)

EZIO-HSCM2

(single counter)

Number of

Outputs

Response Time

PLS Setpoints

Peak Voltage

Maximum Steady

State Output

Current

Maximum

Leakage Current


Maximum Inrush

Current

OFF to ON

Response

ON to OFF

Response


+V Terminals

& Commons

2 Source outputs for each counter

4 Source outputs

100µs

1 on/off pair for each output

50.0 VDC

0.5A per output,


100µA @ 50 VDC @ 50°C

2 VDC @ 0.5A

0.8A for 10ms

< 2µs

<10µs


One V + , 1 Common

Short Circuit

Protection



2500 Volt

Counter Input Specifi cations

Feature

EZIO-HSCM1

(dual counter)

EZIO-HSCM2

(single counter)

Number of

Inputs

Input Voltage

Range

Peak Voltage

5

14-28 VDC

Input Current

40 VDC

2.5 mA @ 14 VDC

5.0 mA @ 28 VDC

Maximum Input

Current


ON Voltage

Level

OFF Voltage

Level


Min. OFF

Current

OFF to ON

Response

ON to OFF

Response


Commons

5 mA @ 28 VDC

5.6KΩ min. @ 14-28 VDC

> 14 VDC

< 2 VDC

2.5 mA

0.2 mA

< 2µs

< 3µs


1 point


Wires

General Specifi cations

2500 Volt


4 of 22 AWG

Operating

Environment

0-60°C, Humidity non-condensing 5-95%

1 Counter Pin Out

Pin

No.

EZIO-HSCM2

(single counter)

1 Quad A encoder 1

2 Quad B encoder 1

3 Inhibit

4 Reset

5 Common

6 Preset

7 Counter 1 Output 1




11 Vs+

(External)

DC INPUT (Source) for Control Signals

(Internal)

Encoder

Output

DC INPUT (Source) for Control Signals

2 Counter Pin Out

Pin

No.

EZIO-HSCM1

(dual counter)

1 Quad A encoder 1

2 Quad B encoder 1

3 Quad A encoder 2

4 Quad B encoder 2

5 Common

6 Preset





11 Vs+

(10-28 VDC)

3

Specifi cations, CPU Operation,

PLC Modes and Memory Map

In this chapter....

• EZPLC Models

• EZIO List

• EZPLC Accessories

• EZPLC Specifi cations

• CPU Overview

• PLC Operation Modes

• CPU Status Indicator LEDs

• Communication Ports

• CPU Operation Sequence

• EZ I/O Response Time

• CPU Scan Time Consideration

• Memory Map

3-2 Chapter 3 - Specs, CPU Operation and Memory Map

3.1 EZPLC Models and EZIO Modules

Part Number Description

EZPLC-A-32

EZPLC-A-32-E

EZPLC-D-32

EZPLC-D-32-E

EZPLC-A-48

4-slot EZPLC AC Powered; 32 I/O Max

4-slot EZPLC AC Powered; 32 I/O Max; with built-in Ethernet




EZPLC-A-48-E

EZPLC-D-48

EZPLC-D-48-E

EZPLC-A-64

EZPLC-A-64-E

EZPLC-D-64

EZPLC-D-64-E

EZPLC-A-96

EZPLC-A-96-E

EZPLC-D-96

EZPLC-D-96-E












EZ I/O Modules

DC Modules

EZIO-8DCI

EZIO-8DCOP

EZIO-8DCON

EZIO-8HSDCI

EZIO-4DCI4DCON

EZIO-4DCI4DCIF

8 point DC Inputs (sink/source)

8 point DC (source) Outputs

8 point DC (sink) Outputs

8 point High Speed DC Inputs (sink/source)

4 point DC (sink/source) Inputs; 4 point DC (sink) outputs

4 point DC (sink/source) Inputs; 4 point High Speed DC (sink/ source) Inputs

4 point DC (Sink/Source) Inputs; 4 point DC (source) outputs EZIO-4DCI4DCOP

AC Modules

EZIO-8ACI

EZIO-8ACO

EZIO-4ACI4DCOP

EZIO-4DCI4ACO

Analog Modules

8 point AC Inputs

8 point AC Outputs

EZIO-4ACI4ACO

AC/DC Combo Modules

4 point AC Inputs; 4 point AC Outputs

EZIO-4DCOP4ACO 4 point DC (source) Outputs; 4 point AC outputs

4 point AC Inputs; 4 point DC (source) outputs

4 point DC (sink/source) Inputs; 4 point AC Outputs

EZIO-8ANIV

EZIO-8ANIC

EZIO-4ANI4ANOV

EZIO-4ANI4ANOC

Relay Modules

EZIO-4IORLO

EZIO-4ACI4RLO

EZIO-4DCOP4RLO

Specialty Modules

EZIO-4THI

EZIO-4HSCM1

EZIO-4HSCM2

8 channel Analog Input module (Voltage)

8 channel Analog Input module (Current)



4 point Relay Outputs

4 point AC Inputs; 4 point Relay Outputs

4 point DC (sink/source) Outputs; 4 point Relay Outputs

4 Channel thermocouple input module



3.2 EZPLC

Accessories

Part

Number

Description

EZPLC-EDIT

EZPLC-M

EZIO-M

EZPLC-CM

EZPLC Programming

Software

Hardware User Manual for

EZPLC CPU and Base


EZI/O Modules


DeviceNet, Profi bus and

Ethernet options

EZPLC-BAT

EZPLC Replacement

Battery

EZP-PGMCBL Programming Cable

EZIO-DUMMY

EZIO-TERM11

Dummy Module for Open

Slots

11 Pin Removable 3.5mm

Phoenix Terminal Block

EZPLC-

TERM5

EZPLC-DN-

TERM5

5 Pin Removable 3.5mm

Phoenix Terminal Block

DeviceNet 5 Pin Field

Terminal Block

Chapter 3 - Specs, CPU Operation and Memory Map 3-3

3.3 EZPLC Specifi cations

Part Number EZPLC-A-32 - Standard

EZPLC-A-32E - Ethernet

EZPLC-D-32 - Standard

EZPLC-D-32E - Ethernet

EZPLC Specifi cations

EZPLC-A-48 - Standard












Specifi cations


4 Slot EZPLC AC

Powered

110 VAC

(95-125VAC)

4 Slot EZPLC DC

Powered

24VDC

(20-28VDC)

4 Slot Base (32I/O Max)

EZPLC models with “E” suffi x are built with 10/100 Base-T Ethernet with a standard RJ45 connector

6 Slot EZPLC AC

Powered

110 VAC

(95-125VAC)

6 Slot EZPLC DC

Powered

24VDC

(20-28VDC)

8 Slot EZPLC AC

Powered

110 VAC

(95-125VAC)

8 Slot EZPLC DC

Powered

24VDC

(20-28VDC)

12 Slot EZPLC AC

Powered

110 VAC

(95-125VAC)

6 Slot Base (48I/O Max) 8 Slot Base (64I/O Max)

12 Slot EZPLC DC

Powered

24VDC

(20-28VDC)

12 Slot Base (96I/O Max)

Maximum I/O

Capacity

Power Supply

Capacity

CPU & Support

Electronics Power

I/O Module Power

(typical)

DeviceNet/Profi bus

Interface Power

Maximum Power

Consumption

CPU Processor

Total Memory

Available

Total Number of

Registers

Typical Scan Time

Real Time Clock/

Calendar

Built-In Battery

Backup

LED Indicators

I/O Supported

10 watts 11 watts

3.3V @ 1 Amp

300mA

25mA

DeviceNet 50mA

Profi bus 100mA

32 Bit, 40 MHz RISC Processor

64 KB (Ladder)

8192 16Bit

3ms (1K Boolean)

Built-in

12 watts

Yes, Lithium coin cell battery with 5 year life expectancy, with a low battery indicator

Input Power, CPU Status (Run, Program & Run/Program) , Low Battery and RS232 Programming Port active indicators

EZI/O Snap-in modules with status LEDs and Removable Terminal Block

DC / AC / Analog / Relay / Thermocouple / High Speed Counter / DeviceNet / Profi bus

15 watts

Operating

Temperature

Storage

Temperature

Humidity

Electrical Noise

Agency Approval

Withstand Voltage

Insulation

Resistance

Vibration

Shock

Protocols

Supported

Communication

Ports

External

Dimensions

5.75” x 4.868” x 3.124”

(146.05 x 123.65 x 79.356mm)

-10C to 60C

-20C to 70C

10-95% Non-Condensing

Nema ICS 2-230 Showering arc; ANSI C37.90a SWC; Level C Chattering Relay Test (pending)

UL, CUL, CE (pending)

1000VDC (1 minute) between power supply input terminal and protective ground)

Over 20M Ohm between power supply input and terminal and protective ground

5 to 55Hz 2G’s for 2 hours in X,Y,and Z axis

10G for under 12ms in the X,Y, and Z axis

ASCII In/Out on RS422/485 port; EZ Protocol on Ethernet and RS232 port

DeviceNet Slave option card (EZPLC-DeviceNet), and Profi bus Slave option card (EZPLC-Profi bus)

Standard Model: Port 1: RS232 (Programming and HMI Port Only with EZ Protocol)

Port 2: RS422 (1.2K, 2.4K, 4.8K, 9.6K, 19.2K, and 38.4K Baud Rates supported) ASCII In/Out

Ethernet Model: Port 1: RS232 (Programming and HMI Port Only with EZ Protocol)

Port 2: RS422 (1.2K, 2.4K, 4.8K, 9.6K, 19.2K, and 38.4K Baud Rates supported) ASCII In/Out

Port 3: Ethernet TCP/IP with EZ Protocol for programming or interface to an HMI

8.35” x 4.868” x 3.124”

(212.09 x 123.65 x 79.356mm)

9.21” x 5.818” x 3.124”

(233.93 x 147.78 x 79.356mm)

14.908” x 5.173” x 3.124”

(378.65 x 131.4 x 79.356mm)


3.4 CPU Overview

All EZPLC models have the CPU built-in and do not require any additional plug-in processors. The CPU is one of the most crucial and important components of the EZPLC. Almost all PLC operations are carried out in the CPU so it is very important to understand its capabilities. This section will provide you with all the information regarding the EZPLC CPU and its communication specifi cations.

The EZPLC is offered in two different types of CPUs. The Standard EZPLC has two integrated serial communication ports while the Enhanced model has an additional port for Ethernet connectivity. The EZPLC CPU offers very robust processing power with a rich instruction set. Refer to Section

5 for the complete set of the 55 most widely used instructions. Common features to all CPU confi gurations include:

• Both CPUs support all 55 instructions, including data conversion, 2

types of drum sequencer, ASCII In/Out communications.

• 64 KB of total program memory with 8192 total registers

• Fast scan time (3 ms of scan time for 1k Boolean instructions)

• Two integrated serial communication ports (Port 1: RS232; Port 2:

RS422/485)

• Enhanced model with Ethernet communication port

• Optional communication interface cards for DeviceNet Slave and

• The CPU is a 32 bit 40 MHz Motorola ColdFire processor.


3.5 CPU Operation Modes

The Mode DIP Switches on an EZPLC are used to switch between Program and Run modes. Use the following table as a guide to different modes.

NOTE: As a stand alone

PLC (as against embedded

PLC) the EZPLC needs to have SW1 set at 1 (ON) and SW2 set at 0 (OFF) In this mode, its RS232 can be used for either programming the EZPLC or connecting it to an external HMI like EZPanel or

EZText. SW1 and SW2 also provide an extra level of safety for EZPLC

Programs. If these switches are set to be both on or off, the CPU is totally disconnected from the RS232

Programming port.

RS232 Programming/Communication Port Enable Switch Setup

SW1

0

1

0

1

SW2

0

0

1

1

PLC Panel

LED LED

Off Off

On Off

Off On

On On

RUN LED

On

Off

Off

Off

Connection

Port disconnected

RS232 to PLC

RS232 to HMI*

Port disconnected

Switches SW1 and SW2 control the connectivity of the RS232 communication/programming port on the EZPLC base to its CPU. Switch

SW1 must be ON and SW2 must be OFF in order to be able to program the PLC from a computer.

*SW2 is provided for a special case when EZPLC is embedded in our

EZPanel or EZText Enhanced.

Once a connection is established between the PLC and computer thru

SW1, switches SW3 & SW4 help the user switch between RUN/PROGRAM modes of the PLC.

SW1

SW2

SW3

SW4

Run LED

PLC LED

HMI LED

Tri-Color LED

NOTE: Shown for 4 and 6 slots, 8 and 12 slot bases have the same orientation except that the switches and LEDs are at the bottom of the motherboard.

PLC Run/Program Switch Setup

1

0

SW3 SW4

0 0

1

0

1

1

Tricolor LED

Off

Green

Red

Amber

Operation/Mode

No Operation

Run

Program

Run/Program

The Program mode disables all I/O and you can modify the logic program in

PLC. Run mode enables all I/O. You can view/monitor the logic program in this mode but you can’t modify it. Run/Program mode enables you to make modifi cations ONLINE with enabled I/O.


CAUTION! CPU LED will be off if there is no valid

Ladder program in the

PLC.

CPU Status Indicator LEDs

EZPLC has 3 Status indicator LEDs. They have specifi c functions that can help you in programming and troubleshooting of an EZPLC. These LEDs provide visual indication of CPU status. The table below lists various states of these indicators.

Indicator

PWR

Status

On/Off

Description

Power connection On/Off

CPU

Low Battery

On/Off

On/Off

CPU functioning On/Off

Backup Battery Voltage Low/OK

Red Power LED indicates that the EZPLC has power.

Green CPU LED indicates that the CPU is executing a valid program. Red Low Battery

LED will momentarily turn on at

Power ON and then stay off if the battery is good. If the battery is low, this LED will turn on.

Communications

Both EZPLC CPU models (standard and enhanced) have 2 built-in serial ports. Port 1 is RS232 that can be used for programming and connecting to HMI. Port 2 is an RS-422/485 port that can be used for networking with marquees, barcode printers, scanners and other ASCII type devices.

Enhanced EZPLC CPU model comes with a built-in Ethernet communication interface (RJ45) along with serial ports. Optional communication interfaces

(fi eld installable) for DeviceNet and Profi bus can be installed in every EZPLC.

(DeviceNet and Profi bus communication interfaces are sold separately P/N:

EZPLC-DEVICENET and EZPLC-PROFIBUS).

These option cards are mounted on the back side of the EZPLC motherboard, right next to the CPU card engine.

Ethernet DeviceNet Profi bus


Serial Port 1 Specifi cation

CAUTION! Keep the signal reference GND wire well protected from external noise by using shielded cable.

Use port 1 for programming the EZPLC. This RS232 port can also be used to connect to an operator interface (like EZPanel Enhanced or EZText

Enhanced). You will need to use an appropriate RS-

232C cable for programming from a PC. (P/N EZP-

CBL for communication with EZPanel Enhanced or

EZText Enhanced ONLY) This port is located on the

9-pin D-shell connector and supports EZ Protocol for communicating with an operator interface.

RS232 Wiring Diagram

Serial Port 2 Specifi cation

CAUTION! Do not connect the GND terminal of this port to any external drive.

Please leave it unconnected right at the port terminal.

Use Port 2 to network AC drives or any other compatible device with multi-drop capability over

RS-422/485. This port has the same communication capabilities of many larger PLCs in a serial port. This port is located on the removable Phoenix terminal block. Port 2 supports up to 38.4k baud rate and has ASCII In/Out capability.

RS422/485 Wiring Diagram

Shield Connected to

Earth Ground on both sides

The RS422/485 port can be accessed from the ladder logic program using

Communication Instructions. See EZPLC Software Manual for information on how to confi gure a port to communicate with an ASCII device.

You will need to specify network properties such as Baud Rate (1200 to

38400), Parity value (None, Odd or Even), Data Bits (7 or 8), Stop Bits (1 or 2) and a Protocol.


3V Lithium Cell Battery under module M2

3.6 Battery Backup

The EZPLC has a built-in 3V Lithium ion cell battery to maintain the system

RAM retain its data when the EZPLC system is without external power.

Typical CPU battery life is 5 years, inclusive of PLC runtime and normal shutdown periods. A Low Battery LED indicator gives a low battery voltage warning.

To replace the 3V Lithium cell battery, perform the following steps:

1. Remove the M2 EZI/O module to access the battery.

2. Connect the EZPLC with a programming computer using an

3. Open the EZPLC Editor software and Save the program on your computer’s

4. Disconnect Power source.

5. Simply remove the old battery from the slot.

6. Gently insert a new battery (P/N EZPLC-BAT) into its place, with the Positive

(+) side upwards.

7. Power up the system and reload the program from the computer.

*NOTE: You can replace a battery without removing the main power to the EZPLC. However, it is always recommended to switch off the main power.

3.7 CPU Operation Sequence

A good understanding of EZPLC’s CPU operating sequence will help you achieve the proper control for your equipment or process.

The fl ow chart on the next page shows the main tasks how the CPU controls all aspects of system operation.

Power-up Initialization

At power-up, the CPU initializes the internal electronic hardware. It also checks if all the memories are intact and the system bus is operational. It sets up all the communication registers. It checks the status of the back up battery. If all registers are go, the CPU begins its cyclic scan activity as described below.

Read Inputs

The CPU reads the status of all inputs, and stores them in an image table.

IMAGE TABLE is EZPLC’s internal storage location where it stores all the values of inputs/outputs for ONE scan while it is executing ladder logic. CPU uses this image table data when it solves the application logic program.

After the CPU has read all the inputs from input modules, it reads any input point data from the Specialty modules like High Speed Counters.


Power Up

Initialize HW

Update Inputs

Read input data from specialty modules

Update date/time

Program CPU

Mode

Run

Execute Ladder

Update outputs

Write output data to specialty modules

House Keeping

Check for watchdogs

Error Checking

Yes

OK

Report Error

Set Register

No

Fatal

Error

No

Yes

Force I/O disable and turn off CPU LED

Execute Logic Program

This segment is also called Ladder Scan. The CPU evaluates and executes each instruction in the logic program during the ladder scan cycle. The rungs of a ladder program are made with instructions that defi ne the relationship between system inputs and outputs. The

CPU starts scanning the fi rst rung of the ladder program, solving the instructions from left to right. It continues, rung by rung, until it solves the last rung in the Main logic. At this point, a new image table for the outputs is updated.

Write Outputs

After the CPU has solved the entire logic program, it updates the output image table. The contents of this output image table are written to the corresponding output points in I/O Modules. After the CPU has updated all discrete outputs in the base, it scans for the specialty modules. The output point information is sent to the specialty I/O like counters.

Immediate Inputs/Outputs

There is a possibility that an input changes after the CPU has read the inputs. If you have an application that cannot wait until the CPU returns for the next input scan, you can use Immediate Instructions.

These instructions do not use the status of the input from the image table to solve the application program. The Immediate instructions immediately read the input status directly from I/O modules and update the Input table with appropriate status of input module read. Similarly,

Immediate Output instructions do not wait for the CPU to complete the ladder scan. Immediate outputs are directly written to the image table and Outputs are updated accordingly.

Subroutines

The CPU executes subroutines when called for in the ladder program.

These subroutines are useful in performing the same logic operation time and time again just upon one call so you do not have to repeat the rung logic over and over again. Subroutines are also useful in executing a logical function, for example check limits, upon receiving an external interrupt from an EZI/O module.

3.8 I/O Response Time

I/O response time is typically defi ned as the time required for the control system to note a change in an input point and update a corresponding output point.

In a majority of the applications, the processor of a PLC responds practically instantaneously to this task. There are some applications that require extremely fast I/O scan times. The following four factors affect the I/O response time of a CPU:

1. The point in the scan period when the fi eld input changes its

state.

2. Delay time for Input module to change state.

3. CPU scan time.

4. Delay time for Output module to change state.


Normal I/O Response Time

See the diagram above. The I/O response time is minimum when the I/O module gets the input change before the Read Inputs portion of the Ladder execution scan cycle. In this case the input status is read, the logic program is solved, and the corresponding output point gets updated.

The total I/O response time is calculated as: I/O Response = Delay in Input module + CPU Scan Time + Delay in Output module

Maximum I/O Response Time

The I/O response time is maximum when the I/O module notes an input change after the Read Inputs portion of the Ladder execution scan cycle.

In this case the input status gets noted only in the following Input scan. The diagram shows an example of I/O response timing for this condition.

The total I/O response time is calculated as: I/O Response = Delay in Input module + 2 times the CPU Scan Time + delay in output module.


How to get the best I/O Response time or Interrupt Scan to Read Input

Using Interrupt subroutines and Immediate I/O instructions is the best way to optimize the I/O Response time of your EZPLC system. The immediate instructions update the I/O points during the ladder logic program execution.

See the EZPLC Software Manual for detailed description of Immediate instructions. The diagram shows how immediate input and output instructions affect the I/O response timing.

The total I/O response time is simply calculated as: I/O Response = Delay in Input module + Instruction Execution Time + Delay in Output module

+ Instruction Execution Time = Immediate Input Instruction Execution +

Immediate Output Instruction + Time for Execution of all Instructions inbetween

The total I/O response time for an external interrupt and a subroutine is calculated as: Delay in Input Module + execution of subroutine + delay in output module. As an example, upon an interrupt you can read the status of an input bit, perform a logical operation on it based upon the value of some other registers, and turn on an output in less than 50µs.

3.9 CPU Scan Time Considerations

The scan time includes all the tasks that are performed by the operating system in a cyclic manner. As discussed previously, each scan cycle is made up of several segments. Each of these segments takes a certain amount of time to execute. Among all the segments, the amount of time it takes to execute the application program is the only one that has maximum infl uence on total scan time. This also happens to be the one segment you can control as a user. If your application needs a smaller scan time, then you should try to choose instructions with as fast execution time as possible. This is because different instructions take different amounts of time to execute. Your choice of I/O modules and system confi guration can also affect the scan time.

If you need to check the scan time, the SR7 register holds the value of the last

CPU scan time. You can display this data value from the logic program.


3.10 Memory Map

A PLC system handles many numbers representing different types of information regarding the process. These process/machine parameters may be anything from status of the input or output devices, timers/counters, or other data values. Before you start programming the EZPLC, it would be helpful if you took a moment to familiarize yourself with how the system represents and stores the various types of data. Each PLC manufacturer has their own conventions for this in their PLCs.

Here we discuss various memory types used in the EZPLCs. These memory types can be used to store a variety of information and can be used inside various RLL instructions. See a description of each of the memory types below.

Discrete Memory Type

A Discrete memory type is one bit that can be either a 1 or a 0 (On or

Off). Discrete memory area is used for inputs, outputs, control relays, and timer/counter bits.

WORD Memory Type

A Word memory type is a 16-bit location that is normally used to store and manipulate numeric or ASCII data. A word memory location is also called a Register.

Mapping Conventions Used

Discrete Inputs

Discrete Inputs are denoted using an “I” pre-fi x (e.g. I1, I4, etc…). The maximum number of Inputs available is 1 through 128. Discrete inputs are

Read only type.

Note: All the discrete type EZIO modules are mapped to

Discrete Inputs. In this example, the Output bit O1 will be turned on when input I1 allows power through the rung.

Discrete Outputs

Discrete Outputs are denoted using an “O” pre-fi x (e.g. O1, O4, etc…). The maximum number of Outputs available is 1 through 128. Discrete Outputs are Read-Write type.

Note: All the Discrete type EZIO Output modules are mapped to Discrete Outputs.


Input Register (Word)

Input Registers are denoted using an “IR” pre-fi x (e.g. IR1, IR4, etc…).

These are 16-bit Word data types (registers). The maximum number of

Input Registers available is 1 through 64. You can only Read from an IR register.

Note: All the EZIO Analog Input, Thermocouple, and High

Speed Counter modules are mapped to Input Registers.

Output Register (Word)

Output Words are denoted using an “OR” pre-fi x (e.g. OR1, OR4, etc…).

These are 16-bit Word data types (registers). The maximum number of

Output Registers available is 1 through 64. OR are Read-Write type of

Word registers.

Note: All the EZIO Analog outputs, are mapped to Output

Registers.

Discrete Internals (Discrete)

Discrete Internals are denoted using “S” pre-fi x (e.g. S1, S4, etc…). There are 1024 Discrete Internals available in the EZPLC. Discrete Internals are read-write type.

Discrete internal bits are mainly used to control the user logic program.

They do not represent a real physical device, like switch, output coil etc.

They are only internal to the CPU. You cannot program discrete internals as discrete inputs or discrete outputs for EZIO modules.

In this example, memory location S1 will be powered when input I1 turns on; you can then use a discrete internal as an input in another rung.


Register Internals (Word)

Internal Registers are denoted using an “R” pre-fi x (e.g. R1, R4, etc…). These are 16-bit Word data types (registers). There are 8192 Internal Registers available in the EZPLC. R are Read-Write type of data registers.

System Discretes (Discrete)

System Discretes are denoted using an “SD” pre-fi x (e.g. SD1, SD4, etc…).

There are 16 System Discretes available in the EZPLC. System Discretes are Read-Write type.

SDs are Read-Write discrete memory locations with pre-assigned functionality. There are many different types of system discretes. They help in logic program development, or provide system operating status information, etc.

System Registers (Word)

System Registers are denoted using an “SR” pre-fi x (e.g. SR1, SR4, etc…). These are 16-bit Word data types (registers). There are 20 System

Registers available in the EZPLC. System registers are Read-Write type data points.

Index and Value Registers (Word)

The Index Register data type is represented by an “XR” pre-fi x (e.g. XR1,

XR2 etc…). There are 4 XR memory locations available in EZPLC 1 through

4. “XR” is a Read-Write data type and it is mainly used to point to the correct address of “R” registers. The pointed-to “R” registers data value is stored in “#R” registers.

Value Register data type is represented by a “#R” pre-fi x (e.g. #R1, #R2 etc…). There are 4 #R memory locations available in EZPLC 1 through 4.

“#R” is a Read-Write data type and it is mainly used to read/write value of

“R” registers as pointed out by “XR” registers.

Both XR and #R registers are used in conjunction with each other and provide a convenient way of addressing R registers.

Example:

Let’s assume data values

Then #R1=9874 (the actual data value of R59)

Then #R2=32 (the actual data value of R8000)


XR contains the address of the operand (or specifi es a register that contains the effective address), #R is used to read or write the actual operand. Indirect addressing is often combined with pre- or post-increment (or decrement) addressing. This allows the address of the operand to be increased or decreased by the specifi ed number either before or after using it. Proper usage of XR variables often saves a lot of programming.


Maintenance and

Troubleshooting

In This Chapter....

• Hardware Maintenance for PLC

• PLC System Troubleshooting

4

4-2 Chapter 4 - Maintenance and Troubleshooting

4.1 Hardware Maintenance

Routine maintenance checks should be performed on the EZPLC to avoid any risk of hardware problems. EZPLC is designed to be a very rugged controller so that just a few checks periodically will help keep it up and running.

The key points to be checked include:

Maintaining the Ambient Operating Conditions

Keeping the EZPLC’s environment within specifi ed operating conditions is the best method to minimize the maintenance.

1. Always ensure that ambient temperature inside the cabinet is within

EZPLC’s temperature ratings.

2. Employ cooling methods like a blower fan to reduce ‘hot spots’ around

the EZPLC, if any other equipment inside or outside of the cabinet is

3. Periodically inspect and clean if there are any air fi lters on the

cabinet. Ensure that the EZPLC is free from dust, humidity and corrosive

gasses.

CPU Backup Battery

It is important that you check the Low Battery LED Indicator periodically. If the

3V Lithium cell battery needs to be replaced, perform the following steps:

1. Connect the EZPLC with a programming computer using an

2. Open the EZPLC Editor software and Save the program on

your computer’s hard disk.

3. Disconnect the Power source.

4. Simply remove the old battery from the slot.

5. Gently insert a new battery (P/N EZPLC-BAT) into its place, with the

Positive (+) side upwards.

6. Power-up the system and reload the program from your computer.

*NOTE: You can replace a battery without removing the main power to the EZPLC, however it is always recommended to switch off the main power.

Error Checking

The EZPLC system performs a standard diagnostic routine during each

CPU scan. This is called the error-checking step. The primary task of this step is to identify various types of CPU and I/O failures. We classify these errors/failures broadly into two categories: Fatal and Non-fatal

Fatal Errors

These errors are the ones that lead to the system failure. During the CPU scan if a fatal error is detected, PLC is automatically switched out of Run mode and all I/O points are disabled. Some instances of fatal errors include:

Wrong parity value, Wrong I/O confi guration, Programming errors, etc.

EZPLC will not go into Run mode from Program if it detects a fatal error.

Chapter 4 - Maintenance and Troubleshooting 4-3

Non-Fatal Errors

These errors just need your attention and are not detrimental to PLC operation. Unlike fatal errors, the PLC will continue in Run mode despite an occurrence of non-fatal errors. When you identify such errors, you can proceed with an orderly shutdown, switch the PLC into Program mode and take the required corrective action. Some examples of non-fatal errors are – Low backup battery voltage, minor programming errors, I/O module error, etc.

4.2 System Troubleshooting

Problem

Operation None of the

LEDs on EZPLC are On.

PWR LED on

EZPLC is Off.

Possible Cause

Disconnected or faulty power source

Suggested Action

Check the wiring for loose contacts and secure if found any.

For 24 VDC powered EZPLC, make sure that proper polarity is observed.

Input power level is outside of EZPLC’s power rating specifi cations

CPU LED is Off.

Incorrect power supply to the EZPLC

Ensure that the power being presented to the

EZPLC terminals is within specifi ed range

Ensure correct power supply per specifi cations

Error in the logic program Check your logic program.

Electrical noise

Pay special attention to Program Control

Instructions and make sure you have used

Next or Return statements at the end of Jump and Subroutine Instructions

Follow instructions to avoid electrical noise in

Chapter 3.

Consider installing an Isolation transformer if you think the noise is making it’s way through the Power source

Check to ensure that RS232 signal GND is not connected to Earth ground, and the shield is connected to Earth ground on both sides

Check to ensure that RS422/485 port signal

GND point is not connected

Improper grounding

CPU Hardware failure

Check and repair power source.

Most noise problems occur due to improper grounding. Follow the instructions in Chapter

3 for grounding guidelines.

Power cycle the EZPLC once to see if an intermittent high frequency noise has caused the failure.

If yes, take proper steps (e.g. grounding, noise fi lters) to reduce the noise.

If problem persists, call EZ Automation for assistance.


Problem

Operation Low Batt LED is On.

Possible Cause

Low battery voltage

LEDs on one or more I/O modules are Off.

Incorrect power supply to the EZ I/O module

Improper installation of module

On-Line programming does not work.

Disconnected or loose wiring

Wrong position of Mode

DIP switches

Communication

No communication with EZPLC

Disconnected or loose cable

No communication with the programming computer

(RS232 Port error)

Wrong/broken cable

Wrong position of Mode

DIP switches

Wrong Comm Port Settings


Follow instructions in the Maintenance section of this chapter to replace the Lithium coin cell battery

Ensure correct power supply per specifi cations

Check the connectors for loose contacts and secure if found any.

Make sure to mount the EZ I/O module properly on the base

Make sure to connect the Terminal block properly on the EZ I/O module


Check if the Tricolor LED near dipswitches is

Green or Amber

Switch SW3 must be in ON (1) position.

Ensure you are using a correct communication cable.


Check if the cable has any broken wires

Replace/repair wiring if not proper

Make sure you are using a correct communication cable. (RS-232C)

Check the pins and wiring on the cable

Make sure if the Run LED near dipswitches is

Off and PLC LED is On


Check if the Tricolor LED near dipswitches is

Green or Amber


Check and correct the comm port attributes

Open the EZPLC Editor and click on the

Confi guration button

Enter/correct parameters like Unit number,

Group number and Comm Port name

Chapter 4 - Maintenance and Troubleshooting 4-5

Communication

Problem Possible Cause

Wrong Comm Port Assignment on the Computer


Check if correct Serial Port (Com1 or Com2) of the computer is selected

No communication with the ASCII device on

RS422/485 network

No communication with the Device

Level Network

Wrong/broken/loose cable Check and correct the wiring to send/receive pins on the RS422 port

Wrong Comm Port

Settings

Ensure right alignment of the Phoenix terminal block on which this port is located

Check and correct the comm port attributes

Open the EZPLC logic program and look for the OpenPort Instruction.

Mismatching comm settings of connected device

Check/correct parameters like Baud rate,

Parity, Data/Stop Bits and protocol

Check if the connected device is sending correct data

Check/correct parameters like Baud rate,

Parity, Data/Stop Bits and protocol on the connected device

Network option board not installed correctly

Wrong Settings -

DeviceNet

Most communication problems occur due to improper grounding. Follow the instructions in

Chapter 3 for grounding of both devices.

Check that the Option board is inserted properly in the slot

Check if the Network type selected is

DeviceNet

Open the Setup -> Device Network menu of

EZPLC Editor

Check/Correct the network properties like

MAC Id, Baud rate etc

Wrong Settings - Profi bus Open the Setup -> Device Network menu of

EZPLC Editor

Check if the Network type selected is Profi bus

Check/Correct the network properties such as

Node address

No communication with the Ethernet network

Wrong Comm Port

Settings

Open the EZPLC Editor and click on the

Ethernet/Confi guration button

Enter/correct parameters like Unit number,

Group number and Comm Port name

Open the Setup -> Ethernet menu of EZPLC

Editor

Check/Correct the network properties such as

IP address, Subnet Mask etc


Still Need HELP?

Technical Support

Most of the frequently encountered problems regarding EZPLC operation are answered in the sections above. However, if you still need answers to your questions, please call our technical support at 1-877-774-EASY.

Warranty Repairs

If your EZPLC is under warranty, contact us at 1-877-774-EASY

Out of Warranty Services

If your EZPLC is out of warranty, contact EZ Automation at 1-877-774-EASY for an evaluation of repair costs. You can then decide whether it is more economical to proceed with the repairs or to upgrade your system with a new EZPLC.

Symbols

4 pt. 110AC Out Module 2-27

4 pt. 110VAC In 2-28

4 pt. 110VAC In, 4 pt. 110VAC Out Module

2-26

4 pt. 110VAC Out Module 2-29

4 pt. 110 AC In/4 pt. Relay Out Modulew/built-in

Electromagnetic shield 2-31

4 pt. 24VDC In 2-29

4 pt. 24VDC In/4 pt. 24VDC Fast Input Module

with 2-22

4 pt. 24VDC In/4 pt. 24VDC Out Module 2-23

4 pt. 24VDC In/4 pt. Relay Out Modulew/built-in


4 pt. 24VDC Out 2-27

4 pt. 24VDC Out Module 2-28

4 pt. Analog In/4 pt. Analog Out Module

4 pt. Analog In/4 pt. Analog Out Module

4 pt. Relay Out Module w/built-in


64KB Memory 1-12

8192 Registers 1-12

8 pt. 110VAC Input Module 2-24

8 pt. 110VAC Output Module 2-25

8 pt. 24VDC High Speed Input Module 2-20

8 pt. 24VDC Input Module 2-17

8 pt. 24VDC Output Module 2-18

8 pt. 24VDC Output Sinking Module 2-19,2-21

8 pt. Analog In Module (Current) 2-34

8 pt. Analog In Module (Voltage) 2-33

A

AC/DC Combo 1-6

AC/DC Transient Protection 2-7

AC Combo 1-6

AC Input 1-6

AC Line Noise 2-7,2-8

AC Output 1-6

Add I/O Simulation 1-9

Agency Approvals 2-4

Ambient Operating Conditions 4-2

Analog Combo 1-6

Analog Input 1-6

Analog Modules 1-8

B

Bases 1-6

Battery Backup 3-8

Blackouts 2-8

Brownouts 2-8

Index

Index

C

Cabinets 2-5

Cabinet Grounding 2-6

Cabinet Wiring 2-6

Cabling 2-5

Choke Isolation 2-5

Communications 3-6

Communication Cards 1-6

Connect Power 1-9

CPUs 1-6

CPU (Card Engine) 1-7

CPU Backup Battery 4-2

CPU Operation Modes 3-5

CPU Operation Sequence 3-8

CPU Overview 3-4

CPU Scan Time Considerations 3-11

CPU Status Indicator LEDs 3-6

D

DC Combo 1-6

DC Input 1-6

DC Output 1-6

DC Powered EZPLC System 2-9

DC Sinking Transient Protection 2-7

DeviceNet 3-6

Disconnecting Main Power 2-2

Discrete I/O Module Status Indicators 2-16

Discrete Inputs 3-12

Discrete Internals (Discrete) 3-13

Discrete Memory Type 3-12

Discrete Modules 1-8

Discrete Outputs 3-12

E

Electrical Considerations 2-4

Electrical Noise 2-4

Enter Program 1-10

Environmental Specifi cations 2-3

Error Checking 4-2

Ethernet 3-6

Execute Logic Program 3-9

EZI/O Modules 2-17

EZIO-4ACI4ACO 2-26

EZIO-4ACI4DCOP 2-28

EZIO-4ACI4RLO 2-31

EZIO-4ANI4ANOC 2-36

EZIO-4ANI4ANOV 2-35

EZIO-4DCI4ACO 2-29

EZIO-4DCI4DCIF 2-22

EZIO-4DCI4DCON 2-21,2-23

EZIO-4DCIP4RLO 2-32

EZIO-4DCOP4ACO 2-27

EZIO-4RLO 2-30

EZIO-4THI 2-37

EZIO-8ACI 2-24

I-1

I-2 Index

EZIO-8ACO 2-25

EZIO-8ANIC 2-34

EZIO-8ANIV 2-33

EZIO-8DCI 2-17

EZIO-8DCON 2-19

EZIO-8DCOP 2-18

EZIO-8HSDCI 2-20

EZIO Installation Overview 2-15

EZIO Modules Positioning 2-13

EZIO Module Dimensions 2-15

EZIO Mounting and Wiring 2-15

EZIO Part Numbering System 1-8

EZPLCAccessories 3-2

EZPLC Base 1-7

EZPLC In Control Cabinets 2-4

EZPLC Models and EZIO Modules 3-2

EZPLC Mounting 2-12

EZPLC Part Numbering System 1-8

EZPLC Specifi cations 3-3

EZPLC System Overview 1-6

F

Fail-Safe Operation 2-2

Fatal Errors 4-2

Free Flow Logic 1-12

G

Grounding 2-5

H

Hardware Maintenance 4-2

HELP 1-6

High Speed Counter Modules with PLS

Outputs 2-38

I

I/O Confi guration 1-7

I/O Modules 1-7

I/O Response Time 3-9

I/O Response time 3-11

Immediate Inputs/Outputs 3-9

Index and Value Registers (Word) 3-14

Input Register (Word) 3-13

Installation Considerations 2-3

Install I/O Modules 1-9

Introduction 1-2

M

Mapping Conventions Used 3-12

Maximum I/O Response Time 3-10

Memory Map 3-12

Mix-n-Match EZI/O 1-11

Module Positioning Restrictions 2-14

Mounting Dimensions 2-12

Mounting I/O Modules 2-15

N

Noise Spikes 2-8

Normal I/O Response Time 3-10

No Power Budgeting 1-11

O

Optical Isolation 2-4,2-5

Organization of the Manual 1-4

Output Register (Word) 3-13

Out of Warranty Services 6

P

Patent No 1-2

Physical Layout of EZPLC 2-4

PLC Run/Program Switch Setup 3-5

Power-up Initialization 3-8

Power Budgeting 1-11

Power Cable Core 2-9

Power connection 2-9

Profi bus 3-6

Purpose of the Manual 1-3

R

Read Inputs 3-8

Register Internals (Word) 3-14

Relay Combo 1-6

Relay Output 1-6

Removable Terminal Blocks 2-16

Removing I/O Modules 2-16

RFI on Electronic Automation Equipment 2-4

Rich Instruction Set 1-12

Routing EZIO Wiring 2-15

RS232 Programming/Communication Port 3-5

RS232 Wiring Diagram 2-5

RS422/485 Wiring Diagram 2-5

S

Safety 2-2

Safety Circuits 2-2

Safety Considerations 2-2

Safety Techniques 2-2

Scan Time 1-11

Serial Port 1 Specifi cation 3-7

Serial Port 2 Specifi cation 3-7

Shielding 2-5

Shielding of Cables 2-4

Sinking (N type) 2-10

Slots Numbering System 2-13

Sourcing (P type) 2-10

Specialty 1-6

Subroutines 3-9

System Components 1-9

System Discretes (Discrete) 3-14

System Registers (Word) 3-14

T

Technical Support 1-3

Test the Program 1-11

Thermocouple Input Module 2-37

V

Voltage Fluctuations 2-8

W

Wiring Capabilities 2-16

Wiring EZIO Modules 2-15

WORD Memory Type 3-12

Write Outputs 3-9

Index I-3

I-4 Index


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