DL05/06 High-Speed Counter

DL05/06 High-Speed Counter
DL05/06 High-Speed Counter I/O Module
CTRIO features
The CTRIO modules offer the following
I/O features:
• 4 DC sink/source inputs, 9-30VDC
• 2 isolated sink/source DC outputs,
5-36 VDC, 1A per point
High-Speed
Counter I/O
Module
Inputs supported:
• 1 quadrature encoder counter up to 100
KHz, or 2 single-channel counters up to
100 KHz using module terminals A, B, C
and D
• High-speed edge timers, dual edge timers,
pulse catch, count reset, count inhibit,
count capture or home search limits using
module terminals C or D
H0-CTRIO <--->
Outputs supported:
• 2 independently configurable high-speed
discrete outputs or 1 channel pulse output
control (20 Hz-25 kHz)
• Pulse and direction or cw/ccw pulses
supported for pulse output control
• Raw control of discrete output directly
from user control program
Overview
The High-Speed Counter I/O (CTRIO)
module is designed to accept high-speed
pulse-type input signals for counting or timing
applications and to provide high-speed
pulse-type output signals for stepper/servo
motor control, monitoring, alarm or other
discrete control functions. The CTRIO module
offers great flexibility for applications that call
for precise counting or timing, based on an
input event or for high-speed control output
applications.
Software
configuration
Typical applications
• High-speed cut-to-length operations using
encoder input
• Pick-and-place or indexing functions
controlling a stepper/servo drive
• Dynamic registration for web material
control
• Accurate frequency counting for speed
control with onboard scaling
• PLS (Programmable Limit Switch) functions for high-speed packaging, gluing, or
labeling
• Sub 10 µsec pulse-catch capability for
high-speed product detection
• Functions for level or flow
Supported systems
Multiple CTRIO modules can reside in the
same PLC, provided the base power
budget is adequate.
DirectLOGIC DL05 and
DL06 PLCs
You can use the H0-CTRIO module with
any of the DL05 and DL06 PLCs.
All scaling and configuration is done via
CTRIO Workbench, a Windows software
utility program. This eliminates the need
for PLC ladder programming or other
interface device programming to
configure the module. CTRIO Workbench
runs under Windows 98/2000/XP and NT
4.0 SP5 or later.
The CTRIO module has its own microprocessor and operates asynchronously with CTRIO Workbench main configuration screen
respect to the PLC/controller. This means that
the on-board outputs respond in real time to
incoming signals so there is no delay waiting
for the PLC/controller to scan I/O.
Configure I/O screen
The H0-CTRIO module is designed to work
with incremental encoders or other field
devices that send pulse outputs.
Use Configure I/O dialog to assign
the CTRIO input and output functions
CPU
DL05
DL06
2–60
Firmware Required DirectSOFT Required
Version 4.60 or later
Version 3.0c or later
Version 1.40 or later
Version 4.0, Build 16 or later
PLC Products
1 - 80 0 - 633 - 0405
DL05/06 High-Speed Counter
PLC
Overview
DL05/06
PLC
DL105
PLC
I/O Specifications
DL205
PLC
General
Module Type
Modules Per Base
I/O Points Used
Field Wiring Connector
Internal Power Consumption
Operating Environment
Manufacturer
Isolation
Limited only by power consumption
4 pts sink/source 100K Hz
Max
Minimum Pulse
Width
Input Voltage Range
Maximum Voltage
Input Voltage
Protection
Rated Input Current
Minimum ON
Voltage
Maximum OFF
Voltage
Minimum ON
Current
Maximum OFF
Current
OFF to ON Response
ON to OFF Response
5 µsec
9-30VDC
30VDC
Zener Clamped at 33VDC
8mA typical 12mA maximum
9.0VDC
2.0VDC
5.0mA (9VDC required to
guarantee ON state)
2.0mA
Less than 3 µsec
Less than 3 µsec
DL405
PLC
None, I/O map directly in PLC V-memory or PC control access
Standard removable terminal block
250mA Max at +5V from base power supply;
(All I/O in ON state at max voltage/current)
32°F to 140°F (0°C to 60°C), humidity (non-condensing) 5% to 95%
Field I/O
Software
Host Automation Products, LLC
2500V I/O to Logic, 1000V among input channels and all outputs
C-more
HMIs
Other HMI
H0-CTRIO Output Specifications
H0-CTRIO Input Specifications
Inputs
DL305
PLC
Intelligent
Outputs
2 pts, independently isolated, current sourcing or sinking
FET outputs: open drain and source with floating gate drive
Voltage Range
Maximum Voltage
Output clamp Voltage
Maximum Load Current
Maximum Load Voltage
Maximum Leakage
Current
Inrush Current
OFF to ON Response
ON to OFF Response
ON State V Drop
External Power Supply
Overcurrent Protection
Thermal Shutdown
Overtemperature Reset
Duty Cycle Range
Configurable Presets
a) Single
b) Multiple
5VDC - 36VDC
36VDC
60VDC
1.0A
36VDC
AC Drives
Motors
Steppers/
Servos
Motor
Controls
100µA
5A for 20ms
less than 3µsec
less than 3µsec
m 0.3V
For loop power only, not required for internal module function*
15A max
Tjunction = 150°C
Tjunction = 130°C
1% to 99% in 1% increments (default = 50%)
Proximity
Sensors
Photo
Sensors
Limit
Switches
Encoders
a) each output can be assigned one preset, or
b) each output can be assigned one table of presets, one table can contain max. 128
presets, max. predefined tables = 255
Current
Sensors
Pushbuttons/
Lights
* User supplied power source required for stepper drive configuration.
Process
H0-CTRIO Output Resources
H0-CTRIO Input Resources
Counter/Timer 2
Resource
Options
1X, 2X, or 4X Quadrature, Up or
Down Counter, Edge Timer, Dual
Edge Timer, Input Pulse Catch, Reset,
Inhibit, Capture
Pulse output / Discrete outputs Pulse outputs: 1 channel (20Hz-25KHz); Discrete outputs: 2 pts.
Resource Options
Pulse outputs: pulse/direction or cw/ccw; Profiles:Trapezoid, S-Curve,
Symmetrical S-Curve, Dynamic Position, Dynamic Velocity, Home Search,
Velocity Mode, Run to Limit Mode and Run to Position Mode
Discrete outputs: configurable for set, reset, pulse on, pulse off, toggle,
reset count functions (assigned to respond to Timer/Counter input functions).
Raw mode: Direct access to discrete output from user application program
Target Position Range
+ / - 2.1 billion (32 bits or 31 bits + sign bit)
Timer Range / 4.2 billion (32 bits); 1 µsec
Resolution
Counter Range
+ / - 2.1 billion
(32 bits or 31 bits + sign bit)
Relays/
Timers
Comm.
TB’s &
Wiring
Power
Circuit
Protection
Enclosures
Appendix
Part Index
w w w. a u to m at i o n d i re c t . c o m / d l 05 a n d 06
PLC Products
2–61
DL05/06 High-Speed Counter
Status indicators
H0-CTRIO LED Descriptions
OK
ER
A
B
Y0 - Y1
H0-CTRIO LED Diagnostic Definitions
Module OK
OK
ERR
Description
User Program Error
ON
OFF
All is well - RUN Mode
Channel 1 Fn1 Status
ON
ON
Hardware Failure
Channel 1 Fn2 Status
Blinking
Blinking
Output Status
Blinking
OFF
OFF
Blinking
Boot Mode - Used for Field OS Upgrades
Program Mode
Module Self-diagnostic Failure
OFF
ON
Module Error Due to Watchdog Timeout
OFF
OFF
No Power to Module
H0-CTRIO LED Diagnostic Definitions
A
B
Y0 - Y1
Blinks when Channel 1 Function 1 is counting or timing
Blinks when Channel 1 Function 2 is counting or timing
Follow actual output state; ON = output is passing current
Installation and wiring
The H0-CTRIO module has one input channel, consisting of four optically isolated input points (pts. A-D on common M). The inputs
can be wired to either sink or source current. The module has two optically isolated output points (pts. Y0-Y1 on common YC).
The outputs must be wired so positive current flows into the YC terminal and then out of the Yn terminal. The module’s internal jumpers
must be set to the High Side Common position for high side switching (sourcing) outputs or to the Low Side Common position for low
side switching (sinking) outputs. Source operation is the factory default setting. See the schematic on the next page for sample jumper
settings.
The module is configured using CTRIO Workbench to accommodate the user’s application. The function of each input (counting,
timing, reset, etc.) and output (pulse output, discrete output, etc.) is defined in the configuration of the module.
See the notes below for further details about power source considerations, circuit polarities, and field devices.
Notes:
1. Inputs (A, B, C, D) require user-provided 9-30 VDC power sources. Terminal M is the common for Channel 1 inputs.
Maximum current consumption is 12 mA per input point.
2. Polarity of the input power sources can be
reversed. Consideration must be given, however, to
the polarity of the field device. Many field devices
are designed for only one polarity and can be damaged if power wiring is reversed.
IN
3. Outputs have one polarity only and are powered by
user-provided 5-36 VDC power sources. The maximum allowable current per output circuit is 1A.
Module output jumpers must be set to the High side
or Low side common position for Source/Sink
applications. Refer to the diagrams on the next
page for sample jumper settings.
D
OK
A
B
A
C
Y1
A
-
+
- +
B
C
M
D
-
+
L
–
+
+
–
YC
M
Y0
YC
Y1
Y0
Y1
L
+
–
PLC Products
Y0
CTR/TMR IN
9–30V 5–12mA
DC/Pulse Out
5–36V 1A
IN
B
OUT
2–62
ERR
–
+
OUT
H0–CTRIO
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DL05/06 High-Speed Counter
PLC
Overview
DL05/06
PLC
DL105
PLC
Solid state input wiring
device
Pulse output schematic
DC types of field devices are configured to
either sink or source current. This affects
the wiring of the device to the CTRIO
module. Refer to the sinking/sourcing
section in the appendix for a complete
explanation of sinking and sourcing
concepts.
DL205
PLC
DL305
PLC
YC
CTRIO
Output
+5 to 36VDC
Yn (where n=0, 1)
Set the module
jumpers
to
Hi
Common
position
when switching the
high side of a DC
load.
DL405
PLC
Field I/O
HI
COM
+V
Software
NPN Field Device (sink)
+
C-more
HMIs
Load
-
This drawing illustrates wiring that is
typical for Channel 1 terminals A, B,
C, and D.
Other HMI
AC Drives
Motors
+
Load
-
LO
Common
0V
A
Sensing Circuit
Steppers/
Servos
Motor
Controls
+5 to 36VDC
24VDC
- +
Yn (where n=0, 1)
M
CTRIO
Output
YC
Set the module
jumpers
to
LO
Common
position
when switching the
low side of a DC
load.
Proximity
Sensors
Photo
Sensors
Limit
Switches
Encoders
PNP Field Device (source)
24VDC
This drawing illustrates wiring that is
typical for Channel 1 terminals A, B,
C, and D.
Sensing Circuit
Current
Sensors
Stepper/servo drive
wiring example
+
Pushbuttons/
Lights
IN
-
Process
A
B
A
C
D
Relays/
Timers
Comm.
Step Amplifier
5-36VDC
OPTO Power
Pulse
+ -
M
YC
Y0
(or CW)
TB’s &
Wiring
Power
M
Y1
Direction (or CCW)
OUT
Enclosures
LO
Common
0V
For this wiring example, the
module jumpers should be set
to the LO Common position.
Circuit
Protection
Appendix
Part Index
w w w. a u to m at i o n d i re c t . c o m / d l 05 a n d 06
PLC Products
2–63
DL05/06 High-Speed Counter
CTRIO Workbench configure I/O setup
Fill-in-the-blank
configuration software
The CTRIO Workbench is the software utility used to configure the
CTRIO module and to scale signals to desired engineering units.
Workbench also allows you to perform various other functions, such
as switching between the CTRIO’s Program mode and Run mode,
monitoring I/O status and functions, and diagnostic control of
module functions. The CTRIO Workbench utility ships with the
CTRIO User Manual. You can also download the latest version free
at the Host Engineering’s Web site: www.hosteng.com.
The Configure I/O dialog is the location where input and output
functions are assigned to the module. The choice of input and
output functions determines which options are available. The
input function boxes prompt you with selections for supported
functions. The Workbench software automatically disallows any
unsupported configurations.
CTRIO Workbench main configuration screen
Select modules from multiple
networked PLCs
H0-CTRIO
Save and load configurations
with Read/Write File feature
Configure I/O screen
Detailed snap-shot of module
status and configurations
CTRIO Workbench diagnostics and monitoring
The Monitor I/O dialog is accessible from the main Workbench
dialog when the module is in Run Mode. This allows for a convenient way to test and debug your configuration prior to installation.
The Monitor I/O dialog is divided into three functional areas: Input
Functions, Output Functions and System Functions. The data
displayed under the Input Functions tab includes all input Dword
parameters, status bits and the current status of each configured
input and output function. The fields displayed under the Output
Functions tab includes all output parameters and configuration
information that can be altered during runtime and the bits that indicate successful transfers or errors. The System Functions can be
used to read from or write to the CTRIO’s internal registers.
Monitor I/O screen
CTRIO Workbench on-board scaling
Scaling raw signals to engineering units is accomplished
using the Scaling Wizard. The Scaling Wizard options are
different for the Counter functions as compared with the
Timer functions. “Position” and “Rate” scaling are available
when you select a Counter function. “Interval” scaling is
available when you select a Timing function.
Scaling Wizard screen
Monitor I/O dialog included
for easy de-bug features
2–64
PLC Products
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DL05/06 High-Speed Counter
PLC
Overview
DL05/06
PLC
High-speed input operations
High-speed counting
The CTRIO module is capable of a wide variety of high
speed input and output operations all within one
module. With its single channel input and separate
single channel output design, the CTRIO can satisfy
both high-speed counting, timing, pulse catch operations, along with high speed discrete output or several
profile choices of pulse output operations. Not all
combinations of input functions and output functions
are possible within the resources of the module, but the
following examples are some of the most common
applications for the CTRIO. Check out these examples
and see how they relate to your high speed application
needs.
The CTRIO can be configured for counting functions for
the use of an encoder input, (up to two quadrature
encoders per module) with available connections for
external reset, capture and inhibit signals. In a simple cut
to length application as shown, the encoder provides an
input position reference for the material to the module.
The module's high speed outputs are wired to the cutting
device and to the clutch and/or braking device. When the
count from the encoder is equal to a pre-programmed
setpoint within the module, the high speed outputs are
activated to stop and cut the material to a repeatable fixed
length. Additionally, the clutch/brake signal can be used
for an inhibit signal to not accumulate counts while the
material is being cut.
DL105
PLC
DL205
PLC
DL305
PLC
DL405
PLC
Field I/O
Software
C-more
HMIs
Other HMI
High-speed timing
The CTRIO can be configured for timing functions
based on count or rate. Using a common configuration
of a proximity switch sensing the teeth on a gear, the
module is able to calculate the velocity of the gear
based on the rate it receives counts. This value can be
scaled within the module to the engineering units
required for the application.
High-speed timing application
High-speed cut-to-length application
AC Drives
PLC with CTRIO module
Motor
Interface
Motor
control
lines
Steppers/
Servos
Motor
Controls
Gearbox, clutch and
brake interface
PLC with CTRIO module
CTRIO high
speed output
Encoder
Photo
Sensors
Limit
Switches
Material to be
cut to length
Proximity switch
Proximity
Sensors
Cutter interface
Cutter assembly
Gear
Motors
Encoders
Photoelectric switch
Using Configure I/O screen to configure
CTRIO for high-speed counting
Current
Sensors
Pushbuttons/
Lights
Process
High-speed edge timing application
Relays/
Timers
Using Configure I/O screen to configure CTRIO for high-speed timing
Comm.
Point-click selections of
hardwired connection for Counting,
Reset, and Inhibit
TB’s &
Wiring
Power
Powerful edge timing functions clicking on the edge button cycles through the
available edge timing functions
Circuit
Protection
Enclosures
Appendix
Part Index
w w w. a u to m at i o n d i re c t . c o m / d l 05 a n d 06
PLC Products
2–65
DL05/06 High-Speed Counter
Pulse output operations
PLC with CTRIO module
Using Edit Pulse Profile screen to select Trapezoid pulse output profile
CTRIO pulse output signals
Fill spout
Stepper or
servo drive
Fill-in-the-blank parameters
allow precise tuning of the output
pulse profile
Circular turn table
Pulse output for stepper/servo control
The CTRIO module is capable of multiple configurations for pulse
output control, most often when connected to a stepper or servo
drive system. The module can deliver a pulse output signal up to a
maximum of 25 kHz with support for pulse-and-direction or
CW/CCW pulses. The available profile choices include Trapezoid,
S-Curve, Symmetrical S-Curve, Dynamic Positioning, Dynamic
Velocity and Home Search. All profiles can be easily configured
using the CTRIO Workbench software with fill-in-the-blank parameter fields and a graphic representation of the selected profile.
Three additional profiles are available that are completely
controlled by the user program (no CTRIO profile is configured).
They are Velocity Mode, Run to Limit Mode and Run to Position
Mode.
Example application
In a simple rotary indexing application, as shown above, a fixed
Trapezoid profile is chosen. The CTRIO for this application is wired
to a stepper drive for pulse-and-direction. The requirement for this
application is to provide a smooth movement of the rotary table to
allow product to be filled into individual containers equal distance
apart. The predetermined number of pulses required for each
movement is entered into the CTRIO Workbench as "Total Pulses"
along with the Starting Frequency, Ending Frequency, and
Positioning Frequency (speed after acceleration). The Acceleration
and Deceleration parameters are entered in units of time, so no
ramp-distance calculations are required. After all parameters are
entered, a graphical representation of the configured profile is
shown automatically. Once the configuration has been downloaded to the module, all that is needed is from the PLC CPU is the
Enable Output signal to begin a movement.
Stepper motor
Stepper motor
inside housing
Rotary indexing liquid fill application
Other common pulse output applications:
• S-Curve accel/decel profile for signaling a stepper or servo drive
that needs a curved acceleration and deceleration profile, i.e. for
diminishing any initial “jerk” upon movement of static products,
boxes on conveyors, liquids in containers on an indexer, printing
registrations, etc.
• Dynamic Positioning for any run-to-a-specific-position requirement, either by a pre-programmed count of an external high speed
discrete input wired to the module. This is popular in winding or
webcontrol with any dynamic registration mark or variable speed
requirement.
• Home search routines to seek a home position based on CTRIO
discrete input limit(s).
Example of S-Curve acceleration and deceleration
pulse output profile
Calculate Profile displays
graphical representation of output
pulse profile
2–66
PLC Products
1 - 80 0 - 633 - 0405
DL05/06 High-Speed Counter
PLC
Overview
DL05/06
PLC
DL105
PLC
Multihead drill machine application
Combining high-speed input and
pulse output operations
DL205
PLC
Using CTRIO Workbench to configure the module
for simultaneous high-speed input and highspeed pulse output operation
DL305
PLC
Proximity switch
DL405
PLC
Proximity switch
Proximity switch
Field I/O
Encoder
Software
C-more
HMIs
PLC with CTRIO module
Other HMI
Stepper motor
AC Drives
Motors
Stepper or
servo drive
Steppers/
Servos
Motor
Controls
High-speed inputs and pulse output
combinations
Example application
In the simple drill-head application shown above, the
CTRIO pulse outputs are wired to a stepper and/or servo
drive. The inputs are wired to an encoder attached to the
lead screw on the movable portion of the drill-head
assembly. The CTRIO module output pulse train to the drive
allows the motor to spin the lead screw, making the drill
move forward into the passing material. The encoder monitors the speed and position of the drill-head. Prox switches
at each end act as limit switches ensuring the drill-head will
not over-travel. A home sensor is positioned in the middle of
the assembly, which allows the PLC to reset the count.
The flexible design of the CTRIO module allows for
combining high speed inputs and delivering high speed pulse
output signals simultaneously. There are limitations to this
type of configuration in that the module does not internally
support closed loop control. Providing closed loop control
with the CTRIO involves additional PLC code to coordinate
this control, making the application subject to the PLC CPU
program scan. Simple position/speed monitoring, via a high
speed counting input for non-critical response, while
providing pulse outputs to a drive, is easily achievable for the
CTRIO.
PLC CPU program
Proximity
Sensors
Photo
Sensors
Limit
Switches
Encoders
Current
Sensors
Pushbuttons/
Lights
Process
Relays/
Timers
CTRIO pulse output profile
Comm.
TB’s &
Wiring
Power
Closed loop control for the CTRIO module requires PLC
CPU program interaction to close the loop. This makes the
application subject to the PLC CPU scan.
Circuit
Protection
Enclosures
Appendix
CTRIO high-speed input pulse train
w w w. a u to m at i o n d i re c t . c o m / d l 05 a n d 06
Part Index
PLC Products
2–67
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