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1. s f Serial Number SEE SWITCH DETAIL V FOR PROPER SWITCH SETTINGS Figure 2 9 RS 232 Host to I O Plexer wiring Host to I O PLEXER RS 232 communications is limited to a distance of 50 Feet The connector for the Host cable marked Host RS 232 See fig 2 5 is a 9 pin female D submin Pin assignments for this connector may also be found on the edge of the cover The Host connection may be a 9 or 25 pin D submin connector depending on whether the AT or XT connection is used A duTec cable can be used for this purpose IOPN AT IOPN XT or IOPN AXT In addition to the Host to I O PLEXER wiring the installer should confirm that the network type switches are set in the RS 232 RPT positions and that both CTS RTS jumpers are in the horizontal position as shown The switches marked Pull up in figure 2 5 should be left in the ON position 2 When distances greater than 50 feet are encountered the Host must be equipped with an RS 422 485 device Installation 2 Modem to I O Plexer RS 232 TxD For Modem Local Set Jp3 connections set y P S Rode DIP switches to jumper to LAST position the vertical position Host RS 232 _ From IL ND miner Eno Not Used x z 10 100 Figure 2 10 link via modem Two handshake control lines are provided on the I O PLEXER for interfacing to modems They are request to send RTS and Cl2. 2 11 Installation 2 I O Plexer to I O Plexer RS 422 Jumper Jp3 used to connect RD RTS to CTS on I O Plexer amp GND Local host RS 232 port Remove TLIS RS 232 to allow modem control ps Prior ERTS of RTS CTS evice L IS RS 232 s an A 2 From ao wood B 4 I From T HH ERIS Next O Num See switch detail for proper settings 200 SRO SND Local TETS RS 198 RS 232 24D STD Host TRIS RS 232 Bots E a TI From z 7 ae Prior meri 8 amp To To Next HI From EE ee x Device sp O eit i Figure 2 13 RS 422 I O Plexer to I O Plexer Wiring Figure 2 13 shows two individually shielded twisted pairs of AWG 24 with an overall isolated shield such as Belded 8162 with the internal shield connected between unit grounds The overall isolated shield should be connected to earth ground in one place only In a perfect wold with no electrical noise and equal ground potentials the signal ground connection would not be required Not connecting signal ground however frequently leads to costly debugging These connections which require the cover to be removed are made by placing a 1 4 inch stripped wire into the openings of the wire clamp terminal block and tightening the screw This block is socketed for easy removal An alternative means for network co
3. Temperature Level Value Waveforms Analog Inputs Determines signal levels with 12 bits resolution Input values can be software offset with 12 bits resolution over the module s specified range The amplitude of input values can be software multiplied by factors ranging from 0 25 to 4 0 The occurrence of input values falling out of user defined upper or lower limits can be flagged The minimum level input values can be captured The maximum level input values can be captured Can calculate average input amplitude for 1 65 535 samples Can linearize in C inputs from thermocouples and RTD s Will also return temperature probe data Analog Outputs Can set output levels as a fraction of the module s full scale range and are specified with 12 bits resolution Analog outputs can provide square triangular sawtooth or ramp waveforms Maximum and minimum amplitudes as a fraction of the output module s full scale range are specified with 12 bits resolution Waveform periods are specified from 0 1 to 6 553 Sec 109 Minutes All waveforms are made up of at least 10 segments One part in 4095 Read Pulse widths Pulse Counting Edge Detection Note Set outputs Modifiers One Shot Delayed Introduction 1 Digital Inputs Read the ON or OFF state of a inputs The duration of a single pulse or total on off time of consecutive pulses can be resolved to the nearest 0 01 seconds for a max
4. RS 422 RS 485 Terminal gt EA emra Pull Alt 422 485 0000 Pull Up Switches Molex Connector i PU Number Set up LED 7 lt 4 Serial Number in Set up Pushbutton Figure 3 1 Connectors Switches and Indicators During the setup phase of an I O PLEXER system the main chassis are given specific values for unit address network baud rate and protocol pass type A momentary pushbutton and seven segment display provide access to these parameters Figure 3 1 shows the location of these components labeled setup pushbutton and sequential display Function addresses Each Host instruction includes an address made up of two hexadecimal characters 00h to Ffh At any I O PLEXER network connection up to 6 different types of functions can be performed each with its own unique system wide function address The address for functions which are not present in a particular chassis is set equal to the master address so as not to occupy valid space There are two I O PLEXER addressing modes OFFSET and VARIABLE Offset Mode Units are shipped in the OFFSET mode where only the master unit control address needs to be set with a range of 00H to 3FH The remaining active function addresses are automatically calculated and set based on the master address Setup 3 Function Abbrev Function Sequential Address Display Master unit digital I O 40H 64 U1 40 1 Digital Expander The OFFSET a
5. U TA 6 7 8 9101112131415 2nd Digital expander e poo o 3 01234567 8 9101112131415 4 st Digital expander unu memes cello 01234567 8 9101112131415 Jr LX 01234567 8 9101112131415 Figure 2 15 Digital Expanders Digital expanders are configured during the main chassis normal setup procedure see section 3 2 14 Installation 2 Module Wiring Analog Inputs Modules should NEVER be installed or removed while power is applied to the I O PLEXER Note Analog modules normally run hot to the touch Correct polarity connections are essential to proper operation of all analog inputs Connections to terminals marked with a must be more positive than the terminals marked with a Thermocouples and RTD s are connected directly to the I O modules with special connectors which insure correct polarity Module status indicators are On dimly when wired correctly and monitoring a valid signal The indicator light may be On brightly off or flicker otherwise Figure 2 16 figure 2 17 and figure 2 18 show the wiring for various types of analog inputs With the exception of thermocouples and RTD s connections are made via the
6. dulec I O PLEXER Innovative I O Since 1977 July 2004 First Revision dulec I O PLEXER Hardware Users Manual 6979 Wales Road Phone 419 666 4700 E Mail info dutec net Northwood Ohio 43619 Toll Free 800 248 1632 http www dutec net Fax 419 666 4702 I O PLEXER Nov 23 2004 Copyright Copyright 2004 duTec inc All rights reserved However any part of this document may be reproduced provided that duTec inc is cited as the source The contents of this manual and the specifications herein may change without notice Trademarks The duTec logo and I O PLEXER are trademarks of duTec inc WINDOWS and WINDOWS 95 are trademarks of MicroSoft Notice to the User The information contained in this manual is believed to be correct However duTec inc assumes no responsibility for any of the circuits described herein conveys no license under any patent or other right and makes no representations that the circuits are free from patent infringement duTec inc makes no representation or warranty that such applications will be suitable the use specified without further testing or modification DuTec inc general policy does not recommend the use of its products in life support applications where failure or malfunction of a component may directly threaten life or injury It is a condition of sale that the user of duTec inc products in life support applications assumes
7. lt Serial Number Set up Pushbutton Figure 2 5 Connectors Switches and Indicators Installation 2 The three choices for communication connections for I O PLEXERs are Repeat Used in RS 422 or RS 485 networks to extend range 5000 feet between segments Also used for RS 232 Host to first unit link if 50 feet Sequential display reads L1 Multidrop Used in RS 422 or RS 485 networks Provides a total network segment range of 5000 feet Sequential display reads L2 Last Unit Must be used in RS 422 and RS 485 networks for the unit most distant from the Host Sequential display reads L3 If there is only one I O PLEXER in a network it is designated as Last Unit For the network layout the sequential display indicates the letter L followed by 1 2 or 3 As shipped I O PLEXERs are setup as L3 Last Unit This change is not part of the push button sequence The displayed value changes from L1 to L2 or L3 only after the DIP switches under the cover have been set and the unit has then undergone a power cycle Installation 2 Communications Wiring Host to I O PLEXER RS 232 Jumper Jp3 used to connect RTS to CTS on I O Plexer Host RS 232 port Remove H Q S to allow modem control of RTS CTS P C TID gt 2 RXD D AA 370 GND 5 GND TRS T RTS CTS 8 CTS co I O Plexer DTR n qu lt
8. For greater distances up to 5000 feet a choice must be made to either equip the Host with an RS 422 or RS 485 card or use an external RS 232 range extender such as the duTec BaudMaster If the Host to first unit link is RS 232 the balance of a network if any can be a mixture of RS 422 and or RS 485 If the Host to first link is either RS 422 or RS 485 The balance of the network if any can be a mixture of RS 422 and or RS 485 For total wire runs less than 5000 feet both RS 422 and RS 485 networks can operate in multidrop mode In this configuration every unit attached to the Host computer is passively connected to the network The benefit to this is that the loss of power to any unit on the network does not affect the ability of other units to respond to the Host computer A drawback to this approach is that the total length of a multidrop segment can only be 5000 feet For ranges greater than 5000 feet some or all of the I O PLEXERs can operate in the repeat mode In this mode the unit plays an active roll in broadcasting the communications signals The length of each network segment connected to a unit in the repeat mode can be up to 5000 feet The limitation of the repeat mode is that a power failure of any single unit disables communications for all units further downstream from the Host Installation 2 Once the physical network media has been chosen a decision as to which units if any will play an active roll in sign
9. are automatically set as shown below 00H MC Master unit control functions Master unit digital I O function display U Master unit analog I O function display U22MA 1 expander digital I O functions display U3 E1 2 expander digital I O functions display U4 E2 3 expander digital I O functions display US E3 in the variable mode individual addresses are independent and can range from 00H to FFH 0 255 Setups Via pushbutton Offset mode only On application of power the IOP flashes Go Go Go Go Go Flashing the pushbutton LED once while the appears places the unit in setup mode the IOP then flashes U 0 MC H HHH Pp the 2 digits after UO is the Master Unit control Hex address the 3 digits after H is the baud rate divided by 100 the 1 digit after the P is the communications protocol type 2 or 4 pass Digit values are changed by flashing the pushbutton LED as they appear note in this method only the MC value is set MD MA and ED are automatically set 40h C 9 Appendix C above each other the display continues to cycle through until there is a full cycle with no changes and stores all values in EEPROM the unit is now in the operational mode and the display cycle becomes U0 MCU1 MDU2 MAU3 EIU4 MFHHHHLLPP Further changes can be made by repeating the pushbutton method The L represents the connection type repeat multidrop last unit Setups Via Local RS 232 Port Offset and Variabl
10. beta teens o t i RD ei ae 1 9 Power Wiring sodes yere id er QU ERE a DER IREQSPEPIS OPER 2 1 Protocol eee ROG PCENA ERN EUER E NE MEE e C 1 Pushb ttOm 2 2a oe e trm eei a n EN ERE REA se te 3 4 REMEDIO NT re eee Arge Ak M 3 6 RS 232 ge spente ce te dt keen Da ee RU E Na 1 7 RS 422 5 4 LAS Tree ER x dee tei Dii Ae ee iu zs 1 7 2 3 2 12 RS 485 seer cdi 2 11 RS 485 oc gut See IA ES van OL eM A we ed 2 13 RT veger ode dc Ar Elevated sere A ai llei 1 9 RID estt ave en E Rote ETUR Eee ES 2 15 RISIGIS v uiuere as as ng ut NIRO 2 9 sequentiakdispl y acid UID ker 3 1 SAP senka dt Wier AI RARO D ERA RR DEAE SUN s 3 4 Setup puslibutton esce t2 e eds EET wile bue laren alien melas hrs RE 3 1 Signal conditioning virus fit A ee EQ UR D e bass 1 2 Index Switches iS oN ds Ae NES 2 12 2 13 Thermocouplen oL pert Neale a atra t UR e avin 1 9 2 15 Trans EED o alee dad ve toa o NA EULA Aa Ge inis M aa n 3 7 Troubleshooting 5 eon c e ee ete alada RO ea bie an 3 6
11. black terminal strip In the case of thermocouple RTD s connections are made directly to the module mating connectors are included There must be nothing connected to the screw terminals corresponding to these module positions The source of analog inputs is external to the I O PLEXER in most circumstances Exceptions are those of RTD and Type 590 temperature input modules where source excitation is supplied within the module Nu CO LOAD cc DI Optional diodes DI to protect CT when module or fuse HO F 19 is removed IVAC IAC IVAC A Voltage Current Figure 2 16 AC current and voltage wiring 2 15 Installation 2 Frequency Voltage Current Source source source sensor sensor sensor HO 9 9 E 100K Ohm 100K 250 Ohm OHM IF10K B Iv50m IF2 5K L Iv100m IFOR L IVI 11420 IF10K L Iv5 Iv10 IV5B IV10B FREQUENCY VOLTAGE CURRENT Figure 2 17 Analog Frequency Voltage and current input wiring ICTD PROBE OMEGA e OMEGA CONN nn CONN TYPE TYPE SMP MTP G e I ITCJ J 1 ITCK K 1 ITR 100 BEN ITCR R 1 ITR 100 1 E ITCS S 1 ITCT T 1 2 ITCE Thermocouple RTD AD590 Probe igure 2 18 Temperature input wiring 2 16 I
12. e PETROLE bai C 8 Communications e o s Sei eere iii tre rare ie e CH ded Pe se 1 7 Communications watchdogs 0 0c cee teen eee eens 1 6 Digital Expander uo RR ee PREM eR E OS 1 1 2 2 2 14 Digital Inp ts V sso ese dto Mes RI RARUS a Rp on s ale Dec te Sa 1 5 Digital Outputs art eo d Ce ice E 1 9 2 19 EfivitOnMenit gt cep E 1 8 Equivalent CITCUIf oL etre rep IU OMNEA ee ub eps v due Y no A 1 Footprint iii ri AR spela And 2 1 Brequency Serket e cam e RA eda bes ERA DERE RICE RA ada en lese go RT 1 9 Hardware watchdog xu sak eae ene TR ERRARE AERA ESSA Grae IESU NS 1 2 I O P rformatnce 2 uas d ves depre ir a A 1 IOPZAD A A A a 1 8 TOPD ae 1 8 TOPDE verre SE dets 1 8 Isolation sd osse A seeren sea DOS NP HERR eae 1 2 IPS sd sia Adal bd ripe p Red Eie 2 9 A gage eet S a Net acie itd Ma Dere sb bek be tidy o at EN er BS 2 9 Local control functions massar ar eerte Eee E Mee iUe TOM Sanna Y dre 1 6 Local RS 232 siro SERENO UI ease adle POSER 1 7 2 9 MAGIC tre AR RERO RN RETINA ERE bis 3 8 Modello vis DUX ELTE Ee pO Ete LE ERE e RC a Kee p Pee 1 7 2 3 2 9 Modem Jumpers terra we ERU UU Ree p Ente Pi ean 3 3 Modules xx arto CN to E CR ta 1 9 Mountilig coni eit a ve eve nasa as A A YA qu re ius 2 1 Network type Witch csi a e em ep SI RR INTRO ROTER ORS F 3 3 OPTO 22 OPTOMUXK s gata eatin aides see ad Rea Deda US POP Salk PS 1 3 Pain rt cds Rhe stolide ute re OR Gas 1 8 Power Supply eec c aie ee ea t id a
13. modules are used to switch external power supply loads on and off Because they contain a protective reverse diode the ODC5 and ODCSA output modules are polarity sensitive and operate correctly only when the terminal is more positive than the terminal A DC digital output module connected backwards conducts current through its protective diode and appears to be uncontrollable it is Polarity does not affect the performance of OAC5 and OACSA digital output modules Because the field sides of output modules are totally isolated from each other like polarities can be wired common to make use of a single power supply It should be noted that the status indicator only follows the logic instruction to the modules and does not show that the module its fuse or external power is present Outputs can only be truly verified by monitoring the output with a multimeter oscilloscope or by employing a digital input module as a feedback tool LOAD LOAD iy dg OAC5 ODC5 OACBA ODC5A OACSR ODC5R OAC5A5 OAC5J AC DC Figure 2 21 Digital output Wiring 2 19 Installation 2 Notes Setup 3 Chassis Setup Local RS 232 Port I O Module Status Sequential Display vr 10201 n j i Host RS 232 Port Network Configuration Switches EII uuu I O Plexer LEX ae RTS CTS Jumpers
14. to I O Plexer wiring The wiring figure shows one individually shielded twisted pairs of AWG 24 such as Belden 8162 with the shields connected between unit grounds In a perfect world with no electrical noise and equal ground potentials everywhere the ground connection is not required Not using the ground connection can lead to costly debugging These connections which require the cover to be removed are made by placing a 1 4 inch stripped wire into the openings of the wire clamp terminal block and tightening the screw This block is socketed for easy removal An alternative means for network connection is to use the 10 pin male connector located behind the clamp terminal block This connector mates with Molex shell number 50 57 9005 and used pins 16 02 0103 As shown in figure 2 12 the terminals of to and from and the terminals of the to and from are connected These connections should not be made in the clamping terminal block or Molex connector alone A combination of the two can be used one for jumpering and the other for the incoming and outgoing connections Another option is to use an external terminal block or leads between the clamp terminal block and Molex connectors In addition to the Host to I O PLEXER wiring the installer should confirm that the network type switches are set in the correct positions multidrop repeat or last unit Refer to appendix A for details concerning the switches marked pull up in figure 2 5
15. to earth ground in one place only In a perfect wold with no electrical noise and equal ground potentials the signal ground connection would not be required Not connecting signal ground however frequently leads to costly debugging These connections which require the cover to be removed are made by placing a 1 4 inch stripped wire into the openings of the wire clamp terminal block and tightening the screw This block is socketed for easy removal An alternative means for network connection is to use the 10 pin male connector located behind the clamp terminal block This connector mates with Molex shell number 50 57 9005 and used pins 16 02 0103 In addition to the Host to I O PLEXER wiring the installer should confirm that the network type switches are set in the correct positions multidrop repeat or last unit Refer to appendix A for details concerning the switches marked pull up in figure 2 5 2 13 Installation 2 Adding Digital Expanders Up to three Digital expanders may be connected to any I O PLEXER which is equipped with a 3 option see page 1 8 These chassis are attached to the main unit via a ribbon cable supplied with the Digital Expander Normally power is supplied through this cable In some circumstances however the Digital Expander is purchased with an optional power supply If so equipped the installer must provide the necessary power connections as well see page 2 2 3rd Digital expander
16. 2 3 g Watchdog Delay setup D 0 2 Sec to 46 6 Hrs convert desired delay to Sec if 655 36 divide by 0 01 Sec convert to hex 14H to FFFFH if 2655 35 watchdog multiplier setup eD instruction must be used then divide desired period by 2 56 Sec convert to hex 14H to FFFFH h Baud Rate local RS 232 Port setup N and network baud rate setup c Desired 300 600 1200 2400 4800 9600 19 200 38 400 baud h value 003 006 012 024 048 096 192 384 j Number of analog averaging samples For analog T convert 1 65535 samples to 4 hex digits for j k analog input level offset slope average 4 hex digits for analog a c d f U L convert each k to decimal subtract 4096 divide by 4095 out of range if 0 or gt 1 multiply by module range for value no input if for analog g h convert each k to decimal subtract 4095 if gt 8 subtract 16 multiply by module range for offset for analog o t Convert each k to decimal divide by 16 for C if 22048 C subtract 4096 If returned analog k was incorrect for analog W divide desired offset by module range if negative add 16 multiply by 4095 convert to hex for analog X Z convert each k to decimal divide by 4096 for analog Y multiply desired slope by 4096 convert to hex lm KR With 1 start 1 stop 8 data bits no parity operates as shipped at 300 baud IOP local port transmits on 2 receives on 3 5 is common C 6 Appendix C Rang
17. 90 Temperature Sensor EE ensor power supply 18 24Vdc BOmA TP590 188 4 to 150 C FIOI Pigital Input output Test Module TP590 1 50 0 to 150 C With field switch and LED When Selecting A power supply for the Fases 4 system assume 25mA for standard digital modules and 100mA for modules marked With an The IDC5ZModule is used for low level signals and will pass signals at the rate of 10Khz The I OPlexer however is limited by Communications baudrate Introduction 1 Notes Installation 2 Installation Mounting In a wall mounted enclosure the I O PLEXER can be mounted horizontally or vertically Horizontal installation is good practice as it makes the best use of natural convection Figure 2 1 below shows the outline of the I O PLEXER Using the keyhole slots the unit can be mounted with 2 10 screws on 16 5 centers Using the corner holes the unit can be mounted with 4 6 or 8 round head or pan head screws located on a 3 5 X 16 5 grid Hole locations in relation to the overall dimensions are shown below Both the I O PLEXER and the digital expander have the same mounting dimensions Corner Mounting Slot Mounting 4 6 32 Screws 2 10 24 Screws ly Je IT NTT O F B 50 350 oF 01234567 8 9101112131415 2 25 II L i E 375 16 5 le 17 25 gt
18. Figure 2 1 I O Plexer footprint Power Wiring Power connections are made at the 3 position terminal block located on the right end of the I O PLEXER No 8 captive wire clamps accept 10 16 AWG wire or spade lugs The terminal block cover need not be removed to install wiring Installation 2 AC Wiring DC Wiring O O io 0 do O zo O oM ok 1415 1415 O O I O Plexer Power supply terminal block Figure 2 2 Power wiring The center terminal block position adjacent to the letter G on the end of the I O module board is chassis earth ground which is connected to the I O PLEXER case Standard 85 132 VAC 47 440 Hz and option ES 105 265 VAC 47 440Hz Operation Following power wiring conventions AWG Black wire to terminal marked H hot White wire to the terminal marked N neutral Green wire to the terminal marked G chassis earth ground Option B or C 10 30 VDC Operation of the power source to the terminal marked H of the power source to the terminal marked N Earth Ground where available to the terminal marked G Digital Expander The I O PLEXER Digital Expander IOP DE Receives its power and signals from the I O PLEXER via the included 24 pin keyed ribbon cable duTec part CE 24 No other power wiring is required See page 2 14 Installation 2 Designing the network In order for the I O PLEXER to share its data
19. H mm 0 C0 Tp 58 N lt eBodackasz Max Values Read Clear Read and Clear Averages Start Complete Read Read Linear C Set temp sensor Type Temp Read Linear C Level Value set all same Read Set Selected Waveforms Squarewave Improved Triangle Up Dn Sawtooth Up Dn Ramp Up Dn Terminate Read all modules De bounce enable De bounce disable gt MAde A K gt MAee A gt MA fel AK gt MATci A gt MAI gt MAUe Au k gt MAoe A k gt MAkcx A gt MA te A LK ANALOG OUTPUTS MAJcl MAKe MASc 1 MAVCApgs MAVelpas MAVeSpas MAve3par MAve7par MAve2par MAve6par gt MAvc0 zal V VV VV V VV V VM PPPPPPPPPP gt P gt DIGITAL INPUTS gt DDM A gt DDeHen gt DDdHe gt ple Pulse Duration Measurements Trig edges set All 45 set Pos 45 setNeg 45 Complete Duration Ctr Read 5 Clear Read and Clear 5 Pulse accum Enable Disable Pulse accum Enable Disable Pulse Counting Counters Read Clear Read and Clear Start Stop Start Stop Freq Counter Enable Freq Counter Disable gt DDae gt DDbe gt DDee gt DDd gt DDee A gt DDge gt DDfe A gt DDeGe gt DDdGe gt DDye gt DDze I4 10 gt gt gt gt gt gt gt l ok gt gt tds sli gt DDdle C 3 AA Aa YES YES YES YES
20. REEN Re 100 TRED 15K lt Bus Transmitter controllod P RS 422 485 CONNECTOR veg in repeat mode Off in multidrop swap o Network Bias L Resistors Te Ss 4 Fve gt From Next o OP TBLK 2 S FBLK To Prior UN U30A 328 Host E 961748 961755 d R37 gt 15K gt Figure A 1 Electrical Equivalent Circuit Figure A 1 Shows the equivalent RS 232 422 Communications circuit for the I O PLEXER When switched to Last Position the 150 Ohm network terminator resistors are in place Positions A D of SW2 allow the removal installation of network biasing resistors used to suppress line noise when all transmitters are at rest These resistors should be left active on at least one but not more than eight units in a single multidrop network segment If more than eight resistor equipped units are present transmitter overloading may occur Appendix A Notes A 2 Appendix B I O Performance The I O PLEXER samples individual analog inputs at the constant rate of 100 samples per second The effective sample rate per channel is determined by the total number of channels to be sampled Input data throughput is based on the time from the beginning of the first character of an instruction to the end of the last character of the response The response time of the Host computer controlling input instructions will reduce the effective throughput Output execution throughput is based on the time from the beginning
21. W Package expanders Ordering Information Specify duTec products by model number IOP AD 1 O PLEXER for analog and digital signals IOP D I O PLEXER for digital signals only IOP DE Digital expander chassis Master must have 3 option Options are specified by a series of suffixes to the model number preceded by a slash For example IOP AD 3 Allows the use of up to three digital expanders on an analog capable I O PLEXER IOP D B Specifies a digital only I O PLEXER with a 12VDC Compatible power supply Introduction 1 Available I O Modules Analog inputs 12 Bit Analog Outputs 12 Bit Voltage Current 0 25mV D1420 Dutput 4 20mA Self Sourcing 0 50mV nto 275 Ohm Load Digital Inputs Inpur 9 5 V po J npurBipolarziy pc dT CCS 28 140 Vac 56 280 V DC5NP t 10 32 15 32 utput 0 1V self sourcing utput 0 10V self sourcing butput 0 10V self sourcing SST lt lt ce Iz 3 S B 3 EN EXER sels 5 Vdc a bee cal nput 4 20 mAdc Digital Outputs Input 0 SAac AC gt i Type EU i0 IST ype K 100 0924 LLL weRwwwwc Pe Type S 0 to 1760 C ODCSR lectro Mechanical 0 5A Relay Form A NO Type T 200 to 224 C Special Purpose C D Type T 120 to 400 TCT 2 Type T 0 to 150 C solated source I 00 Ohm PT 50 to 350 C DCSZ nput 200mV 0 10Khz 100 Ohm PT 0 to 100 C ss digital TR100 1 Type 5
22. YES YES YES YES YES YES YES YES YES YES YES YES YES YES YES YES Appendix C Edge Detection N Edge latch Setall gt DDNe A Yes O Set Off to On gt DDOe A Yes P Set On to Off gt DDPe A Yes Q Read gt DDQ Ac Yes S Clear gt DDSe A Yes R Read and Clear DDRe Ac Yes Event Logging wA Set Reset DDwAe A No wB Read Buffer DDwBe Av w No wC Clear DDwCe A No DIGITAL OUTPUTS J Outputs On Off All Mod DDJe A Yes K Outputs On gt DDKe A Yes L Outputs Off gt DDLe A Yes Z Waveforms One shot On 56 DDZeHn A Yes Off 5 gt DDZeJn A Yes Delayed On 56 gt DDZeln A Yes Off 5 DDZeKn A Yes Squarewave 5 DDZeLtu A Yes Fast Squarewave 8 Bit 5 gt DDZeMtu A Yes Fast Squarewave 16 bit 5 gt DDZeNtu A No Terminate gt DDZeG A Yes h Re trigger time delay gt DDhe A Yes I Pulses 50 duty cycle 5 gt DDictn A Yes k Start Pulse On 5 gt DDken A Yes 0 Off 5 gt DDlcn A Yes 1 Maximum message length is 80 characters 2 Use to generate a CrLf within a message 3 Non Printing ASCII characters can be transmitted using a before the 2 hex character ASCII value 4 Adjacent pulse durations can be accumulated by using Digital y after setting up trigger edges Digital a b or c 5 Affected by setup n TRM Time resolution multiplier 6 Waveform action initiated by Digital J K or L 7 Saved on EEPROM For a complete reference
23. al transmissions This is to say whether the unit will re broadcast or repeat signals which it does not originate Figure 2 4 illustrates the possible networks that can be created by specifying multidrop or repeat functionality for an individual unit gt FromHost i ToHost f lf Tl y From To from To From To From To Host Host Host Host Host Host Host Host Multidropped Multicropped Mulidropped Multidropped JoHost FromHost rl pla From To From To From To From To From To From To Prior Net Prior Next Prior Next Repeat Repeat Last X ToHost 4 4 TT omHost I From To From To From To From To prior prior Prior Next Host Host IOP IOP IOP Multidropped Repeat LAST Figure 2 4 I O Plexer Network Types Installation 2 Network Type Switches Based on the selected network configuration each I O PLEXER must be set up before communications can begin This is done with the network switches shown below in figure 2 5 I dn 1090 RS 422 RS 485 Terminal gt Alt 422 485 Molex Connector Set up LED OTT Local RS 232 Port VO Module Status Sequential Display y 8 Host RS 232 Port A x Network Configuration Fe Switches See TT I O Plexer i sa RTS CTS Jumpers Selector 1 I Pull Up Switches 5 Serial Number
24. all risk of such use and indemnifies duTec inc against all damage Warranty duTec inc warrants its products to be free of defects in materials and workmanship for a period of two 2 years from the shipment date DuTec inc at its option will repair or replace all material found to be defective All repair or replacement must be performed by duTec inc personnel Any parts determined by duTec inc to be defective as a result of abuse misuse or attempts to repair will be repaired at the expense of the customer DuTec inc will not be held liable for any consequential incidental or special damages mis Table of Contents Overview suele ever dda ee vad xd debet oe des 1 1 Capacity idee ails uel dom reme ale wae ed eee snm vua 1 1 VO Signal Compatibility 1 2 Built in Diagnostics LL 1 2 Easy Setups skroget Satset M EE GSP DAS 1 3 Protocol Compatibility 1 3 Available I O Functionality LL 1 4 Analog Inputs Riley kw Mas Eu ae 1 4 Analog Outputs scc lI e p E LEY re ETT 1 4 Digital Inputs sok PL TIR REISEN 1 5 Digital Outputs drsa esda ras ener tae rica Kee ds uds 1 5 Extended capabilities ooooooooooooommorommmmmmoo 1 6 Communications watchdogs LL 1 6 Specifications a sab va dee bas Rae ber us o das EP Dee eae ets vas 1 7 Communications til bui Deo ae Ii beds DS 1 7 POWef xoi me teas x up vu ER dat Webs NE 1 8 Environment sacs ull Vedi EE A 1 8 Packages Jue dies ue enero Lav aod Shas edeb Sen u
25. ay Analog gt MADcg A Yes m Pos Levels Analog gt MAmc 1 A Yes cD WDM Del gt MCeD A NO multiplier 256 dD Disable gt McdD A NO cJ WDM Del gt IOeD A NO multiplier 256 dJ Disable gt IOdD A NO n TRM Timer Res gt DDny A Yes Multiplier cA Address Tag Enable gt MCeA A NO dA Disable gt MCdA A NO eC Chksumtag Enable gt MCeC A NO dc Disable gt MCdC A NO eE Error Msgs Off gt MCeE A NO dE On gt MCdE A NO eF Save setup Enable gt MCeF A NO dF Disable gt MCdF A NO a Var Add Set gt MCaMCMD AMCMDMA NO 7 MAEIE2E3 EIE2E3 b Read gt MCb AMCMDMA NO E1E2E3 Serial I O N Local Port Baud Rate gt MCNh A NO O Host to Slave Msg 123 gt MCO Msg A NO P Msg for Host No 1 gt MCP A NO Yes MCP A Msg NO PP Partial gt MCPP A Msg NO PA Control Codes gt MCPA A Msg NO ANALOG INPUTS L Input value Read gt MALe A k YES g Offsets Calculate gt MAg A k YES W Set MAWc k A YES h Calc and Set gt MAhe A k YES X Gain slope Calculate gt MAXe A k YES Y Set gt MAYc k A YES Z Calc and Set gt MAZe A k YES N Range limits Set gt MANclm A YES O Read errors gt MAO Acd YES Q Clear Errors MAQe A YES P Read and Clear gt MAPe Acd YES a Min Values Read gt MAae A k YES b Clear MAbe A YES c Read and Clear gt MAce A KO YES Appendix C RFOCmH OA lt ORS eH d
26. d 1 8 Ordering Information 42 322 09x dagli Laga E RI UR VHS 1 8 Options sos p E ere eda PSP RT A 1 8 Available I O Modules sssesseeeeeeee ee 1 9 Installation rost lee WW be WI 1 1 Mountings save dag nex pam ada Lat WR LR AER LET EET 2 1 Power Wiring pls ds cee bl ELI IE ER DEG DAS 2 1 Digital Expander i sere eI p IR Tia dera 2 2 Designing the network 2 3 Maultidrop y ini Gilet ei Na ih 2 5 Repeatis so siero gay dans da ao ao duk 2 5 Network Type Switches 4 225 rm sda tae e ee ee E tae UG 2 6 Repeat du otv sb Ibl IRL ee A I EE NDA 2 7 Multidrop vaks sire RID I Ro gs ely Dod oon gee vie 2 7 Last Unit sista sd od vM sed tu 2 7 Communications Wiring 0 cece e 2 8 Table of Contents RS 232 Host to I O Plexer wiring LL 2 8 Modem to I O Plexer RS 232 1 0 0 cece eee 2 9 RS 422 Host to I O Plexer wiring 2 10 Host to I O Plexer RS 485 2 0 kee eee 2 11 RS 422 I O Plexer to I O Plexer Wiring 2 12 RS 485 I O Plexer to I O Plexer wiring 2 13 Adding Digital Expanders 2 0 0 0c cece ee ee eee 2 14 Module Wiring 153 4 IS vesat ss vas boas apartes wae OE da 2 15 Analog Inputs zi lid is DGS Gat 2 15 Analog outputs siii le bey e p Eg d 2 17 Digital Inputs Seb ion Ee See uda rd 2 18 Chassis Setup spino Kst Fide ea at dame i 2 1 Baud rate juss von b Sees sashes b viere 3 1 3 3 Setup pushbutton sais 0 0 20 LL 3 1 Sequential display sa
27. d twisted pairs of AWG 24 such as Belden 9729 with the shields connected between unit grounds In a perfect world with no electrical noise and equal ground potentials everywhere the ground connection is not required Not using the ground connection can lead to costly debugging These connections which require the cover to be removed are made by placing a 1 4 inch stripped wire into the openings of the wire clamp terminal block and tightening the screw This block is socketed for easy removal An alternative means for network connection is to use the 10 pin male connector located behind the clamp terminal block This connector mates with Molex shell number 50 57 9005 and used pins 16 02 0103 In addition to the Host to I O PLEXER wiring the installer should confirm that the network type switches are set in the correct positions multidrop repeat or last unit Refer to appendix A for details concerning the switches marked pull up in figure 2 5 2 10 Installation 2 Host to I O Plexer RS 485 nS Jumper Jp3 used to connect RD RTS to CTS on 1 0 Plexer GND Local Jp3 must be installed TS RS 232 when using RS 485 or All Connections RS 422 communications are to 37 Host to 5 GND and to RS 232 80 is p ED From GND Prior n a STe ETE E L3 E amp Not Used Von 10 O 0000 LA See switch detail for proper settings Figure 2 12 RS 485 Host
28. ddressing mode is more convenient to use as only one address setup is required for each network connection For example changing the Master Unit Control MC from 00H to 03H will automatically cause MD 43H MA 83H DI C3H D2 D3H D3 E3H Variable Mode In the VARIABLE mode function addresses are independent of each other and can range from 00H to FFH For this mode each function MC MD MA D1 D2 and D3 must be entered As long as addresses are not duplicated they can take on any of the 256 possibilities The VARIABLE mode must be used with some software packages and systems of more than 16 I O PLEXER network connections The loading of selected function addresses into the I O PLEXER is explained after the description of baud rates and protocol handshake type found on page 3 4 Any function address not supported by the unit will default to the master unit control address to conserve network address usage Setup 3 Baud Rates Any one of the standard baud rates of 300 600 1200 2400 4800 9600 19200 or 38 400 can be used for the serial network communications The sequential display indicates the letter H followed by the baud rate divided by 100 As shipped I O PLEXERs are setup for 9600 baud the sequential display indicates H096 Changing the baudrate is described beginning on page 3 4 Protocol handshake types Two protocol handshake types are available 2 pass and 4 pass 2 Pass The Host transmits an instruct
29. digits t squarewave On period Digital L ZeL ZeM ZeN u squarewave Off period digital ZeL ZeM ZeN For Digital ZeL divide period in seconds by 2 56 convert to 2 hex digits For digital I ZeM divide period in seconds by 0 01 TRM Convert to 2 hex digits For digital ZeN divide period in seconds by 0 01 TRM Convert 4 hex digits v The number of samples contained in response w Individual sample 4 hex digits representing 16 bits C Appendix C x Temperature sensor type analog k Thermocouples RTD Sensor Sensor E I 3 E TELLE LS Jr NES 12 10 Tro y Timer resolution multiplier TRM Setup a The basic 0 01second resolution of ALL instructions noted with 5 are multiplied by y of setup n default value is 1H range is from 1H to FFH 1 255 z response codes from Setup F identify station type z 00 01 02 03 Type DD Digital MA Analog MC Setup 6 Firmware version number x yy z Q Chassis ID Type No of expanders and firmware version COMMUNICATION PROTOCOL There are two communications protocols 2 pass and 4 pass both of which use only ASCII characters units are shipped in 2 pass the most commonly used the instructions transmitted by the Host are identical for both protocols they differ in their responses 2 Pass A correctly received instruction returns an A and data if any and instruction is executed an incorrectly received message returns a response message and th
30. e instruction is not executed 4 Pass A received instruction is echoed and not executed until Host returns an E non E s cancel instruction CHECKSUMS Automatic Calculation Method The setup eC command puts correct checksum at the end of the N02 error message assemble instruction for which checksum is needed in usual manner but enter XX for the N02 response message has the correct checksum tagged on Manual calculation method See appendix A of the I O PLEXER user guide Defeat Checksum Enter in the position of instructions a checksum error message will never be returned a RISKY PRACTICE Appendix C Special Responses A special response negates transmitted instruction N00 Power has been OFF NOI Invalid command N02 Checksum error N02 Checksum error Correct checksum if setup eC enabled N03 Instruction contains gt 80 characters N04 Non Printable Characters in instruction N05 Invalid instruction length check data fields N06 Communication watchdog time out N07 Invalid data in instruction field N08 Invalid module analog v s digital N09 Power has been OFF battery backed restart OK NIO Local control function error N11 Local control function error N12 Local RS 232 port buffer full ADDRESSES BAUD RATE PROTOCOL Setup There are two addressing modes Offset and Variable units are shipped in the Offset mode where only MC the master unit control needs to be set and MD MA El E2 and E3
31. e limit Output Amplitude 3 Hex digits for analog J N S setup divide desired level by module range multiply by 4095 convert to hex digits for I for analog N high limit is 1 low limit is m for analog K Convert each to decimal divide by 4095 multiply by module range n Counts delays durations periods for digital e f convert each n to decimal multiply bu 0 01 TRM for time in seconds for digital eH divide desired filter period in seconds by 0 01 TRM convert to 4 hex digits for digital el divide desired timebase period in seconds by 0 01 TRM convert to 2 hex digits DAh Hz for digital k l Divide desired period in seconds by 01 WDM convert to 1 4 hex digits For setup m divide desired watchdog delay in seconds by 0 01 WDM convert 0 4 Hex digits for digital X W convert each n to decimal for counts for digital Z divide desired period in seconds by 0 01 TRM convert to 1 4 hex digits n 0 or 1 has special case see user manual waveforms Analog V amplitude determination Peak and Valley p waveform peak or maximum amplitude q waveform valley or minimum amplitude divide desired max for p or min for q bu module range multiply by 4095 convert to 3 hex digits waveforms analog V period determination r sawtooth period ramp duration Multiply period in seconds by 10 convert to 4 hex digits s squarewave and triangle wave period Multiply period in seconds by 5 convert to 4 hex
32. e modes On application of power the IOP flashes Go Go Go Entering Ctrl C from an RS 232 device 8 when the appears places the unit in setup mode RS 232 Device display shows U0MC U1MD U2MA U3ED U4MF HHHH PP Enter only values to be changed using the Exact format as the display and press Enter the RS 232 display shows the values and asks OK Y N S Y stores the new values in EEPROM operational mode starts N re starts the process as if Ctrl C had been entered S Generates standard offset address Address setup via network Variable mode only Instruction setup a can set all 5 addresses at one time it is sent to the current MC address its response lists the new values including the new MC if it was also changed in case forgotten MC is always displayed this method stops the Offset mode the pushbutton method can be used to return to the Offset mode PRECAUTIONS Never Use An upper case letter O for the number 0 An lower case letter for the number 1 an upper case character for a lower case one Appendix C Notes 2 P NPE 3 3 APA rmm 3 3 Addressing saknr SS ea SS Gs C 5 Analog Inputs iine he t ole elses aoa t a i Hb d beads 1 4 1 9 2 15 Analog Outputs ee Dee te rtr tut eet tette t ea eb ed troie Nas 1 4 1 9 2 17 O PRISE passe ped E age UP PUE ebbe 3 3 Cabling costs c6 Salo Sh GaN EU ee E NA MEAM 1 1 Chassis Setupzos tace qa eared eid BRN QU le SNE toe 2 1 CHECKSUMS oca Sian ates stod Pr a ero utate
33. ear to send CTS An active high RTS signal from the I O PLEXER advises the modem that data is available When the modem is ready to accept data it places its CTS line active high to the I O PLEXER thus initiating the data exchange In addition to the modem to I O PLEXER wiring the installer should confirm that JP3 RTS CTS Jumper is positioned as shown in figure 2 10 Jumper JP5 RTS CTS for the local RS 232 port should remain in the horizontal position unless the RTS CTS pair is needed in the device connected to the local RS 232 port A cable for most modem applications the IOP RT cable is available from duTec The switches marked Pull up in figure 2 5 should be left in the on position Note If the modem must make use of the RTS CTS hardware handshake only one I O PLEXER can be used per modem If more than one I O PLEXER is used at a given remote site care should be taken that the modem does not need the RTS CTS handshaking or external hardware will be required Installation 2 Host to I O Plexer RS 422 Jumper Jp3 used to connect Er RTS to CTS on I O Plexer 5 6ND Local Jp3 must be installed 185 RS232 when using RS 485 or All Connections o RS 422 communications are to Fe and to SEND n5 232 D Prior Y See switch detail for proper settings Figure 2 11 RS 422 Host to I O Plexer wiring The wiring figure shows two individually shielde
34. ed below c d e In instructions 1 s specify which positions are affected for setup m analog which outputs are set to specified values for setup m digital which outputs are set to set ON for setup G to O which modules are configured as outputs for setup G to MC which modules are analog for digital a which input durations trigger on positive edges for digital J which modules are to be ON for digital N which outputs latch ON to OFF for digital T which start counting In instructions 0 s specify which positions are affected or for setup G which modules are configured as inputs for setup H I which modules are not to be configured C 5 Appendix C or setup m digital which outputs are to be set OFF or digital a which input durations trigger on negative edges or digital J which modules are to be OFF for digital N which outputs latch from Off to ON or digital eG dG which inputs have pulse accum enabled disabled or digital eH dH which inputs are to be de bounce enabled disabled for digital T which inputs stop counting In responses 1 s indicate for setup j which positions are outputs or digital d analog I which positions are complete or digital M which modules are ON or digital Q R which positions have been triggered or c of analog O P which positions are over limits or d of analog O P which positions are under limits f Turn around delay setup C For delay in mSec 0 10 100 500 set f to 0 1
35. er H show the baud rate divided by 100 initially set for 1200 baud 012 The 1 digit after P signifies the handshake protocol type initially set for 2 pass 2 The display continues to cycle through its sequence until there is a full cycle with no changes The I O PLEXER then stores all values in EEPROM for automatic use following the next power cycle Setup 3 The unit is now in the operational mode and the sequential display cycle becomes U4 d0 U5 EO H012 Address Setup via network VARIABLE mode only Each function address including the master control address of the I O PLEXER can be set individually by using a special instruction to the current master control address of that chassis This set variable address instruction should be used with caution as it will change the unit address and save them in the EEPROM see appendix C C Consult the I O PLEXER protocol manual for details In the event that the new addresses become lost they will appear on the sequential display The pushbutton method can always be used to return to the OFFSET mode Hardware Error Codes When the I O PLEXER is initially turned on it goes through internal self test If anything is not correct the appropriate error code will flash on the sequential display Try recycling power if that does not resolve the error condition please call duTec Technical support at 800 248 1632 Factory default values for an IOP AD 3 depicted i
36. ge In transmission response MAGIC will also capture groups of instructions into macros to be sent automatically These macros can be named and stored for future use making them handy for system setup and local control functions The disk is located in the back of this manual 3 5 diskettes are shipped standard To install this software create a directory called MAGIC and copy the contents of the diskette to that directory MAGIC will prompt the user for the communication port it has been reported that Com 3 and Com 4 may not behave properly with MAGIC of the Host computer the baud rate the master control address of the I O PLEXER Once all of this information has been entered the user is ready to start building instructions and sending them to the I O PLEXER Note The MAGIC software has not been revised for quite some time and therefore has not been updated with some of the more recent features of the I O PLEXER This includes digital expanders 2 and 3 Appendix A Equivalent Communications Circuit i SW3C SW3E a SW3D vec j P gt neon bis lt Resistors Transmitter controlled LI in repeat made vec swa Off in multidrop gt To Next d R54 0P n 10K rm TRED F GREEN ua2c STA Ras TGREEN 961758 961745 IR i From Prior SW2A x host d S RI FRED S 15k F GREEN TYEL TBLK FBLK FYEL i 3 T G
37. guide see the duTec protocol manual C4 Appendix C Addressing See below for hardware setup Each I O PLEXER contains up to 6 units each with its own address a two letter address code a two letter address code is shown for each instruction These indicate which of the 6 addresses are used they are listed below MC Master unit control functions Factory setting 00Hex ry 8 Master unit digital I O functions Factory setting 40Hex E2 2 Digital expander functions Factory setting DOHex 3 digital expander functions Some instructions have counterparts in more than one unit DD This instruction exists for MD El E2 E3 This instruction exists for MD MA El E2 E3 This instruction exists for MC MD MA El E2 E3 Applies to all units addressed in this I O PLEXER use MC See below for setup Instruction response data fields c d e Multiple position fields Each module position maps to a digit in a 16 digit bit number Each digit or bit is a 1 or 0 only This number is then converted to 4 digit numbers Each four numbers is converted into a hex digit For e leading hex zeroes can be omitted Module 15 14 13 12 1110 9 8 7654 3210 Char 2 Char 3 Char 4 Char Bit pattern 0000 0001 0010 0011 0100 0101 0110 01r Hex Digit 0 1 Bit Pattern Hex Digit 8 9 In all position fields 1 s specify which positions are affected and 0 s are disregarded unless they are list
38. ion to an I O PLEXER If the message is correctly received IE valid address instruction type and correct checksum the I O PLEXER executes the instruction and returns the letter A and a carriage return or where data is to be returned the letter A followed by the data followed by a two character checksum ending with a CR 4 Pass The Host transmits an instruction to an I O PLEXER If the message is correctly received IE valid address but not necessarily the correct instruction type or checksum the I O PLEXER returns an A followed by the echo of the instruction and does not execute it If the Host then transmits an E the command is executed in the same manner as 2 pass If the Host returns any other character to any unit on the network the instruction is disregarded The sequential display indicates the letter P followed by 2 or 4 As shipped I O PLEXERS are set up for 2 pass the sequential display indicatesP2 The actual setting of the handshake protocol type into the I O PLEXER is detailed beginning on page 3 4 Network type switch The digit after the L in the sequential display represents how the network switch under the cover plate is set See page 2 7 Note The seven segment display will not reflect a switch position change until power has been cycled to the unit Modem Jumpers If modems are not being used the jumpers should remain in place as shipped in a horizontal position See page 2 9 Setup 3 Changing set
39. ll system status and generate the system displays and reports This is particularly valuable for systems using modems of communications Communications watchdogs The I O PLEXER can be instructed to implement alarm and fail safe states in the event of a communication failure Introduction 1 Specifications Network Communications duTec supports several standards for transmitting serialized I O data between the Host computer and the I O PLEXERs In addition to hardwiring built in modem control lines allow the use of telephone fiber optic and radio modems at baud rates of up to 38 400 ro bal da RS 422 1 524 RS 485 1 524 Unlimited In addition to network communications a separate local RS 232 port with the same baud rate capabilities provides the means for Host communications with local serial devices such as keypads printers or displays Actual interaction with these devices is controlled via the Host computer in the form of character strings embedded in standard protocol instructions It is not possible to directly access the analog and digital I O data from the local RS 232 Port However this data can be obtained by the Host computer and relayed to the auxiliary device connected to the local RS 232 port Device pinout for this port can be found on the cover plate Data format is 8 Databits 1 Stop and no parity Introduction 1 Physical Characteristics 85 132 Vac 30W 47 440Hz 47 440Hz Option C 18 36 Vdc 35
40. n this example Setup 3 Troubleshooting Establishing communications is without a doubt the most difficult process encountered when installing an I O PLEXER system Every component in the system plays a key roll in this function The following steps should aid in the troubleshooting an I O PLEXER system Install the unit nearest to the Host computer Connect appropriate communications network and set the unit address and baud rate to the desired values At the Host computer run a terminal emulation program such as Windows TM V3 x Terminal usually found in the ACCESSORIES program group or Windows 95 Hyper Terminal usually found in the PROGRAMS ACCESSORIES menu path Configure the terminal program for the appropriate comm port baudrate 8 data bits 1 stop bit no parity handshake hardware or none Set the terminal preferences for local echo so that the typed characters can be seen Set the carriage return translation CR to add Linefeed CR LF to both the inbound and outbound transmissions This will scroll each line sent and received rather than overwriting the previous for clarity Once the Host terminal software is configured press the space bar and observe the lower left bargraph segment marked recv On the first YO PLEXER chassis If this LED flashes each time the spacebar is pressed then assume that the communications link to the I O PLEXER is O K If not verify the wiring comm port and modem link if a
41. nnection is to use the 10 pin male connector located behind the clamp terminal block This connector mates with Molex shell number 50 57 9005 and used pins 16 02 0103 In addition to the Host to I O PLEXER wiring the installer should confirm that the network type switches are set in the correct positions multidrop repeat or last unit Refer to appendix A for details concerning the switches marked pull up in figure 2 5 2 12 Installation 2 VO Plexer to I O plexer RS 485 Jumper Jp3 used to connect 30 RTS to CTS on 1 0 Plexer SGND Local host RS 232 port Remove 20 TETS RS 232 to allow modem control From Prior ERTS of RTS CTS 280 Device 59 p 5 GND lost TRIS RS 232 ESTS 5 ys 22 From r g 2 prior mmm El To DOSSI 13 From Kap iii See switch detail for proper settings 2 790 DD SGN Local SIS RS 188 RS 232 22D E sono Host res RS 232 BOTS Du m EM di z From DEN A ETT To Next I From 5 B GND Device rn O 000 Figure 2 14 RS 485 I O Plexer to I O Plexer wiring Figure 2 14 shows one individually shielded twisted pairs of AWG 24 with an overall isolated shield such as Belded 8162 with the internal shield connected between unit grounds The overall isolated shield should be connected
42. nstallation 2 Analog outputs Modules should NEVER be installed or removed while power is applied to the I O PLEXER Note Analog modules normally run hot to the touch Both voltage and current output modules provide their own isolated power output This eliminates the need for external power supplies and insures electrical isolation between each output This also makes it possible to wire voltage outputs in series to obtain larger voltage swings consult application support Module status indicators blink briefly when outputs are updated It should be noted that the status indicator only reflects the TTL data stream to the modules This in of itself does not indicate the actual value of the output signal Output can only truly be verified by monitoring the device to be controlled using a multimeter oscilloscope or employing an analog input module as a feedback tool OV5 500 Ohms Min OV10 2K Ohms Min Voltage Current Load m Load Current IG Load T i Vs 02A Rt 275 Ohm m ca cn Ov1 0i420 0i420 OV5 OV10 Voltage Current For Loads Self gt 275 Ohm Sourced Figure 2 19 Analog Voltage and current output wiring 01420 analog output modules will drive up to 275 ohms If the loop resistance exceeds 275 ohms and external power supply must be added as shown in figure 2 19 Correct polarity is essential 2 17 Ins
43. ny A typical problem here is wrong com port or incorrect wiring of the Host end of the link If the Recv LED is on constantly the RS 422 485 wiring is probably backwards Once signal to the I O PLEXER is verified a valid instruction should be sent to the unit to initiate a response Send an Identify station type F instruction see appendix C C Be sure to send the entire instruction within 10 seconds as the I O PLEXER will ignore instruction that take too long to finish If the instruction is to a valid address for this unit and at the correct baud rate the transmit LED should flash immediately after the carriage return of the instruction is received Setup 3 If no response is received by the Host but the trans LED flashes check the receive wiring or the Host receiver Once a proper response is received at the Host repeat the procedure for any additional I O PLEXER to be added to the network When all chassis are checked out the terminal software can be replaced with the actual Host software for this project Setup 3 MAGIC software utility The MAGIC software is provided as a tool to help the user become familiar with the I O PLEXER instruction set This program incorporates a menu driver step by step approach to building any instruction Once an instruction is developed it may be sent to the I O PLEXER MAGIC will then report the I O PLEXER s response to that instruction thus completing one Host to I O PLEXER exchan
44. o cus fiat steps wee boas weeds TH 3 1 Protocol handshake types LL LL 3 3 Modem Jumpets nh sas cia Yee ip vH DW seere YR 3 3 Changing setup parameters 0 0 cee eee ee ene 3 4 Equivalent RS 232 422 Communications circuit A 1 VO Performances uc agobia ves bb see lea ee Stee sage bios eae A 1 Instruction Format ss sees steve ios dq bep eee dae eg Pg enh B 1 iv Introduction 1 Overview I OPLEXERSs are a family of small completely self contained industrial grade remote data acquisition and control systems which exchange data with a Host computer via a serial communication link Controlled by a Host I OPlexers are located near the sensors and actuators The serial link eliminates the need for expensive and noise prone field wiring between sensors and actuators and a central control room In applications such as remote process monitoring factory automation and energy management a variety of signals must be transmitted over long distances Instead of requiring expensive multi conductor sensor wiring for each signal cabling costs can be reduced significantly by using I O PLEXERs and a single communications circuit One of the most useful features of the I O PLEXER is that in addition to gathering raw data it can be instructed to perform many ranging and statistical operations on the data before it is given to the Host thus allowing the Host to spend less time manipulating numbers and mo
45. of the first character of an instruction to the time when an actual output changes Because the instruction acknowledgment response occurs before outputs actually change state processing time of the Host computer controlling output instructions can reduce the effective throughput The tables below show msec per channel and channels per second for 1 and 16 I O channel cases Digital M 16 Ch mSec chan 16 chan Sec o ER Ww N Appendix B Baud asi m om Input analog L Output analog S Rate 1 Ch 16 Ch IOP mSec Chan Sec od ha o C Chan Sec Chan fi Appendix B The equations below can be used for determining mSec for any number of channels Throughput for digital I O is independent of the number of channels 15 characters Oits D BaudRate 0 00 Ins 1000s Figure B 1 Digital Input Data Time for 1 16 Channels 1 1 Characters 10 Bits k Cu BaudRate 0 01 2 s 1000 s Figure B 2 Digital Output Execution 1 16 Channels Throughput for analog I O varies with the number of channels n 15 aracters 4 aracters annels fl AI Rate a i AT t 10 006 ns 10005 Figure B 3 Analog Input Data Time for n Channels 11 N 10g Obs 11 characters E di Channels 1 pis Jor ton mS Figure B 4 Analog Output Execution n Channels The system throughput for systems with a mixture of analog and digital data is determined by the sum of the time for each in
46. r Can generate 1to 65 535 50 duty cycle pulses whose equal ON and OFF periods can range from 0 01 to 2 55 Sec Resolution can be further multiplied by a factor of 1 256 on a system wide basis Extended capabilities In addition to operating under control of a Host option L of the I O PLEXER has the ability to perform local control functions without the Host Local control functions LCF s can insure the continued safe operation of closed loop control should the Host or its communication link fail In addition the LCF s can substantially reduce Host computational load or communications traffic Once characterized local control function blocks enable the I O PLEXER to perform control tasks without the constant involvement of a Host computer After configuration and activation via Host instructions LCF s take data from their input port and perform computations and send the results to their outputs where they may drive output modules or other I O PLEXER internal functions Utilizing the LCF s to perform simple logic tasks such as analog comparisons the summations differences sequence generating or multiple state machine operations eliminates the need for programmable controllers or special purpose circuitry This capability allows a more effective use of the Host computer and its communication link because the LCF s handle the operation of the designated control function In the meantime the Host is only required to monitor over a
47. re time gathering them Also the I O PLEXER is able to spend more time exposed to the data which in turn allows it to base its responses to the Host on more samples of data The I O PLEXER may also be directed to manipulate the outputs in specific ways to produce delayed or repetitive effects Capacity Each I O PLEXER Master unit will hold any mix of 16 analog or digital electrically isolated input or output modules which can interface to a wide variety of sensors and actuators The I O PLEXER Digital Expander in an identical enclosure provides an additional 16 digital I O module positions for each master unit Up to three Digital Expanders can be attached to each master chassis See Page 1 8 For ordering information I O PLEXER networks can service over 4000 analog and or digital I O Lines in various Combinations Product Test Every I O PLEXER is burned in while operating in a a network of a period of 24 hours at 70 C prior to shipment Introduction 1 Every I O module is tested while its operating environment temperature is cycled over the specified operating range of 0 C to 60 C for a period of 24 hours A computer record is maintained for every analog I O module Throughput System response or throughput for the I O PLEXER can be calculated using appendix B I O Signal Compatibility I O PLEXERs use duTec I O modules to match signal requirements exactly With a direct interface to sensors no external signal condi
48. struction using these equations B 3 Appendix B Notes B 4 Appendix C Instruction Format Q All instructions terminate with a carriage Checksum 2 characters Variable data fields in lower case italics underlined data battery saved with option M and eF instruction Instruction 1 or 2 characters in BOLD Address analog digital etc in upper case ITALICS Response format 2 pass communications protocol Q Q All responses terminate with a carriage return Checksum if data field present l Data field depends on function and instruction type A l l l l Acknowledgment of correctly received instruction Response message N Returned if checksum error or other fault SETUP Instructions Function Instruction Response OPTO22 Equiv A Power up Clear gt AUA A Yes B Reset gt AUB A Yes C Turn around Delay gt LUCf A Yes F Identify type gt AUF AZ Yes G Configure analog VS gt MCGc A Yes digital G Configure all modules gt IOGe A Yes H Configure as inputs gt IOHe A Yes I Configure as outputs gt IOle A Yes j Read module gt Ioj Ac Yes configuration v Read chassis ID gt MCv AQ NO Y Read firmware version gt MCY ABO NO c Set network baudrate7 gt MCch AO NO E Protocol 2 Pass 7 gt LUEO A Yes 4 Pass 7 gt LUE A Yes Appendix C Watchdog Function Instruction Response OPTO22 Equiv m Pos Delay Digital gt DDmcn A Yes D Pos Del
49. tallation 2 Digital Inputs Modules should NEVER be installed or removed with power applied to the I O PLEXER The source of the discrete signal to be monitored is external to the I O PLEXER in most circumstances The IDCSS digital input dry contact sense module is an exception It provides its own current for sensing contact closure Therefore an external supply is not needed In fact they can be DESTROYED if an external source is connected The IDC5 and IDCSD input modules are polarity sensitive and operate only when the terminal is more positive than the terminal Polarity does not affect the performance of the IAC5 IACSA or the IDCSS input modules Because the field sides of input modules are totally isolated from each other like polarities can be wired common to make use of a single power supply The wiring and operation of digital input modules can be verified by closing individual input sensing contacts and observing the change on the nodule status indicators They are On when the module input circuit is energized C PH 7 cm a om IAC5 IDC5D IAC5A IDC5NP IDC5Z IDC5S AC DC DC Dry contact Sense Figure 2 20 Digital Input Wiring 2 18 Installation 2 Digital outputs Modules should never be installed or removed while power is applied to the I O PLEXER ODC5 ODCSA OACS and OACSA digital output
50. tioning is required Furthermore all duTec modules feature total electrical isolation both module to logic and module to module Analog modules are available to measure Millivolts DC to hundreds of volts AC Milliamps DC to amps AC Frequency to tens of KHz Temperature with all popular thermocouples and resistive temperature devices A full range of industry standard digital modules is available for AC DC and dry contact inputs and outputs to hundreds of volts Thermocouple modules provide a cold reference junction compensation I O PLEXER instructions provide linearized thermocouple and RTD sensor data Engineering unit conversions are handled at the Host level Built in Diagnostics On power up the unit self tests for system faults and reports via a sequential display Should hardware or firmware fail an on board hardware watchdog provides safe shutdown by turning off all outputs Normally ON modules are available for those loads that must remain ON Introduction 1 Easy Setup The I O PLEXER has its own power supply no need to purchase or reserve space for an external supply A push button and an on board LED indicator configure unit address and baud rate Removable terminal strips allow attachment removal of multiple cable sets in one step This modularity greatly reduces troubleshooting and upgrade delays Protocol Compatibility The I O PLEXER instruction set core complies 100 with the OPTO 22 OPTOMUX serial comm
51. total of 10 9 min or 46 6 Hrs with multiplied resolution Positive or negative edges initiate measurements The time scale can be multiplied by a factor of 1 2560n a system wide basis Pulses can be counted up to a total of 65 535 To be reliably counted pulses must have a minimum On and minimum OFF times of 1 msec Thus the maximum counting rate for a 50 duty cycle squarewave with equal ON and OFF times for a total of 2 msec would be 500HZ Off to On and On to Off transitions can be detected within 1 msec of their occurrence Action is only reported each 10 msec The response time performance of digital input instructions can be limited by the delay in the input modules themselves which can have ON plus OFF delays of up to 40 msec Digital Outputs Can set individual or multiple outputs ON or OFF Can generate ON or OFF pulse durations of up to 655 35 seconds with a resolution of 0 01 seconds Resolution can be further multiplied by a factor of 1 256 on a system wide basis Can generate delayed ON or OFF outputs of up to 655 35 seconds with a resolution of 0 01 seconds Resolution can be further multiplied by a factor of 1 256 on a system wide basis Introduction 1 Squarewave Can generate squarewaves with programmable ON and OFF periods On and OFF periods have a base range from 0 01 to 2 55 seconds Resolution can be further multiplied by a factor of 1 256 on a system wide basis Re Triggering is available Pulse Generato
52. unications protocol for remote data acquisition and control With speak only when spoken to protocol which only uses ASCII printing characters a Host transmits inquiry requests to the I O PLEXER to determine the status of its various process inputs Based on the reported status the Host makes control decisions and transmits this data as instruction messages to the I O PLEXER which uses the new decisions to make the proper changes to its various actuators Both the Host and the communications link are essential elements in this data acquisition and process control scheme Originally the protocol only allowed for all analog or all digital I O chassis Depending on application requirements each I O PLEXER can respond to up to five different function addresses With their abbreviations they are MC Master Unit Control function address MD Master Unit Control digital I O function address MA Master Unit Analog I O function address El 1 Expander Digital I O function address E2 2 Expander Digital I O function address E3 3 Expander Digital I O functions address It is the multiple function addressing capability of the I O PLEXERs that allow s them to utilize without modification software developed for competitive products Similarly I O PLEXERs can operate simultaneously on the same network with these products Introduction 1 Available I O Functionality Input Value Offsets Gain Slope Range Limits Minimums Maximums Averages
53. up parameters via pushbutton During setup the user may need to change the unit address serial link baud rate and protocol pass type The pushbutton located under the removable cover is used to change these parameters The pushbutton causes the adjacent red LED to flash each time it is pushed Any changed values are automatically saved in non volatile EEPROM During the diagnostic test period following the application of power the sequential display shows GoGoGo Flashing the pushbutton LED once when the Appears places the unit in setup mode The value of each setup character can be changed as they appear in sequence by pressing the pushbutton The display will continue to cycle through the setup sequence until there is a full cycle with no changes The I O PLEXER then stores all values in EEPROM for automatic use following each power cycle If desired changes were not implemented correctly line power can be recycled and setup via pushbutton procedure can be repeated as required Once the unit has been placed in setup mode as described above the value of each setup character shown below can be changed U0 00 H 096 P 2 Only the underlined digits may be changed The 2 digits after UO indicates the master unit control address initially set for address OOH 00 Note In the address offset mode only the master unit address is set The other addresses are automatically set 40H above each other see page 3 2 The 3 digits aft
54. with the Host computer it must be linked via a serial connection This link can be hard wired using an RS 232 link less than 50 Ft or an RS 422 485 twisted pair connection where the wire run between devices is less than 5000 Feet In situations where distances are greater than 5000 feet or circumstances do not allow additional wire to be installed RS 232 Radio or telephone modems may be used In any event the appropriate transmitter of the I O PLEXER will be connected to a suitable receiver of the Host computer as shown in figure 2 3 Ex I O PLEXER saa Bh tom Outputs si a lt ES 9 Pm yk lt gt E Lam qu TS lt gt 42 X lt gt Te lt a Ao lt gt coe as LI ed E lt gt EL Inputs ca Serial a Link Figure 2 3 Typical installation Multiple I O PLEXER Master chassis can be networked together to service large numbers of I O Points Installation 2 The serial communications link between a Host computer and a network of I O PLEXERs can use various combinations of 3 wire shielded RS 232 dual twisted pair plus recommended ground shield RS 422 or single twisted pair plus recommended ground shield RS 485 The Host to first I O PLEXER can be any of the three but because most Hosts are equipped with an RS 232 port This is used most often providing the distance is less than 50 feet
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