ADLINK PCI-7260 User Manual

PCI-7260

8-CH High-Power Relay Outputs &

8-CH Isolated Digital Inputs Card

User’s Manual

Manual Rev. 2.01

Revision Date: December 21, 2006

Part No: 50-12019-100

Advance Technologies; Automate the World.

Copyright 2005 ADLINK TECHNOLOGY INC.

All Rights Reserved.

The information in this document is subject to change without prior
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Table of Contents

1 Introduction ........................................................................ 1

1.1 Features............................................................................... 2

1.2 Applications ......................................................................... 3

1.3 Specifications....................................................................... 4

1.4 Software Support ................................................................. 6

Programming Library ...................................................... 6

DAQ-LVIEW PnP ............................................................ 6

2 Installation .......................................................................... 7

2.1 What you have..................................................................... 7

2.2 Unpacking............................................................................ 7

2.3 PCB Layout.......................................................................... 8

2.4 AC/non-AC filter setting (JP1).............................................. 9

2.5 Isolated digital input connector (JP2)................................. 10

2.6 Relay status output connector (JP3).................................. 11

2.7 Board ID (S1)..................................................................... 12

2.8 Initial state DIP switch (S2) ................................................ 13

2.9 Emergency shutdown state DIP switch (S3)...................... 13

2.10 Connector Pin Assignments (CN1).................................... 14

3 Register Format................................................................ 15

3.1 I/O Address Map................................................................ 16

3.2 Relay Output Control Register........................................... 17

3.3 WDTimer Load Config Register......................................... 18

3.4 Relay Output Read Back Register ..................................... 19

3.5 Emergency Shutdown Setup Register ............................... 20

3.6 Isolated Digital Input Register............................................ 21

3.7 COS Setup Register .......................................................... 22

3.8 COS Latch Register........................................................... 23

3.9 Interrupt / WDT Control Register ....................................... 24

3.10 Interrupt / EMG_SHDN / WDT Status Register ................. 26

3.11 Handling PCI Controller Registers..................................... 27

4 Operation Theorem .......................................................... 29

4.1 Non-Latching Relay Output ............................................... 29

4.2 Emergency Shutdown........................................................ 30

4.3 Watchdog Timer ................................................................ 31

4.4 Isolated Digital Input .......................................................... 32

Table of Contents i

4.5 Interrupt Architecture ......................................................... 33

4.6 Change of State(COS) Interrupt ........................................ 33

5 C/C++ DOS Libraries......................................................... 35

5.1 Programming Guide........................................................... 35

Naming Convention ...................................................... 35

Data Types ................................................................... 35

5.2 _7260 Initial ....................................................................... 36

@ Description ............................................................... 36

@ Syntax ...................................................................... 36

@ Argument .................................................................. 36

@ Return Code ............................................................. 36

5.3 _7260_DO ......................................................................... 37

@ Description ............................................................... 37

@ Syntax ...................................................................... 37

@ Argument .................................................................. 37

@ Return Code ............................................................. 37

5.4 _7260_DO_Read_Back ..................................................... 38

@ Description ............................................................... 38

@ Syntax ...................................................................... 38

@ Argument .................................................................. 38

@ Return Code ............................................................. 38

5.5 _7260_DI ........................................................................... 39

@ Description ............................................................... 39

@ Syntax ...................................................................... 39

@ Argument .................................................................. 39

@ Return Code ............................................................. 39

5.6 _7260_COS_Channel........................................................ 40

@ Description ............................................................... 40

@ Syntax ...................................................................... 40

@ Argument .................................................................. 40

@ Return Code ............................................................. 40

5.7 _7260_COS_Latch ............................................................ 41

@ Description ............................................................... 41

@ Syntax ...................................................................... 41

@ Argument .................................................................. 41

@ Return Code ............................................................. 41

5.8 _7260_INT_Control............................................................ 42

@ Description ............................................................... 42

@ Syntax ...................................................................... 42

ii Table of Contents

@ Argument ................................................................. 42

@ Return Code ............................................................. 43

5.9 _7260_CLR_IRQ ............................................................... 44

@ Description ............................................................... 44

@ Syntax ...................................................................... 44

@ Argument ................................................................. 44

@ Return Code ............................................................. 44

5.10 _7260_GET_IRQ_Status................................................... 45

@ Description ............................................................... 45

@ Syntax ...................................................................... 45

@ Argument ................................................................. 45

@ Return Code ............................................................. 45

5.11 _7260_WDTimerSReload_Config ..................................... 46

@ Description ............................................................... 46

@ Syntax ...................................................................... 46

@ Argument ................................................................. 46

@ Return Code ............................................................. 46

5.12 _7260_EMG_SETUP......................................................... 47

@ Description ............................................................... 47

@ Syntax ...................................................................... 47

@ Argument ................................................................. 47

@ Return Code ............................................................. 47

5.13 _7260_EmgShdnDipSwitch_status ................................... 48

@ Description ............................................................... 48

@ Syntax ...................................................................... 48

@ Argument ................................................................. 48

@ Return Code ............................................................. 48

5.14 _7260_InitDipSwitch_status .............................................. 49

@ Description ............................................................... 49

@ Syntax ...................................................................... 49

@ Argument ................................................................. 49

@ Return Code ............................................................. 49

6 Appendix........................................................................... 51

6.1 Relay Contact Protection Circuits ...................................... 51

RC Circuit ..................................................................... 51

Diode Circuit ................................................................. 52

Diode & Zener diode Circuit .......................................... 52

Varistor Circuit .............................................................. 53

Table of Contents iii

List of Tables

Table 1-1: Digital Input Specifications ........................................ 4

Table 1-2: Relay Output Specifications ...................................... 4

Table 1-3: Power Supply Specifications .................................... 5

Table 1-4: General Specifications .............................................. 5

Table 1-5: Power Consumption Specifications .......................... 5

Table 2-1: The jumpers and DI channels ................................... 9

Table 2-2: Board ID Setting Conditions ................................... 12

Table 2-3: Pin Assignment of PCI-7260 CN1 .......................... 14

Table 3-1: PCI-7260 Register Map .......................................... 16

Table 3-2: Interrupt Source Set Up .......................................... 25

Table 5-1: Data Types ............................................................. 35

iv List of Tables

List of Figures

Figure 2-1: PCI-7260 PCB Layout ............................................... 8

Figure 2-2: Default Input Signal Jumper Setting .......................... 9

Figure 2-3: Isolated Digital Input Connector .............................. 10

Figure 2-4: Relay Status Output Connectors ............................. 11

Figure 2-5: Board ID setting ....................................................... 12

Figure 2-6: Initial State DIP Switch Setting ................................ 13

Figure 2-7: Emergency Shutdown State DIP Switch Setting ..... 13

Figure 4-1: 1 Coil Non-Latching Relay (RESET Condition) ....... 29

Figure 4-2: 7260 Card with EMG_SHDN Trigger....................... 30

Figure 4-3: CPLD with WDTimer Function................................. 32

Figure 4-4: Photo Coupler.......................................................... 32

Figure 4-5: Dry contact .............................................................. 33

Figure 4-6: COS Timing ............................................................. 34

List of Figures v

1 Introduction

The PCI-7260 is a high-power non-latching relay actuator and iso­lated digital input card for industrial automation and machine con­trol.

This PCI-7260 provides 8 high-power non-latching relay outputs
and 8 opto-isolated digital inputs. The relay outputs are SPST­NO+SPST-NC (1 Form A 1 Form B) type and each channel is
capable to switch up to 5A current at 250VAC or 30VDC. The sta­tus of each relay output is indicated by either an on-board LED or
an external relay status output channel. When the non-latching
relay is in CLOSE condition, the corresponding on-board LED will
be turn ON and the corresponding relay status output will be set
as HIGH.

All of the digital input channels are identical non-polarity opto-iso­lated. Each of them is jumper selectable to use a AC filter or non­AC filter. All channels are isolated and therefore are suitable for
collecting digital inputs in noisy environments. The function of
“Change-of-State” (COS) interrupt is provided, which will generate
an interrupt to the host system when any of these digital inputs
changes its state.

Some advanced features for industrial applications are designed
for the PCI-7260. The emergent shutdown input (EMG_SHDN) on
the front panel lets users get back to a safety state set by a DIP
switch regardless the system condition. The initial output status
when powering on can be also set by a DIP switch. And the built-in
watchdog timer guarantees you that all the relays go back to the
safety state when your compute halts.

The I/O connectors are also considered. The 18-pin pluggable
connector for relay outputs and emergency shutdown on the front
panel allows easy wiring and high current carrying. Two extra 20­pin ribbon connectors provide capacities of isolated digital inputs
and relay status outputs.

Introduction 1

1.1 Features

The PCI-7260 high-power relay outputs and isolated digital inputs
card provides the following advanced features:

X Supports universal 32-bit 3.3V and 5V PCI bus

X 8-CH high power relay outputs

Z 5A at 250VAC

Z 5A at 30VDC

X 8-CH isolated digital inputs

X 8-CH relay status outputs

X 1-CH emergent stop input

X Pluggable connector for high current input

X On-board LEDs for relay status display

X Initial and safety state setting by DIP switches

X Interrupt generated from

Z COS (Change of State)

Z CH0 & CH1 positive edge

X Built-in watchdog timer

X Jumper selectable AC-filtered/non-AC-filtered for digital

inputs

2Introduction

1.2 Applications

X Industrial ON/OFF control

X External high-power relay driving & signal switching

X Laboratory automation

X Industrial automation

X Switch contact status sensing, limit switch monitoring,

X Cooperating with A/D and D/A cards to implement a data

acquisition & control system

Introduction 3

1.3 Specifications

Digital input

Input channels 8

Photo-coupler PC-3H4

Input current

Input Voltage

Input impedance

Input mode Isolation AC-filter/ Non-AC-filter

Isolated voltage 2,500 Vrms channel-to-system

Table 1-1: Digital Input Specifications

50 mA max. for isolated input

Relay Output

Output channels 8

Relay type 8 Non-latching SPST-NO + SPST-NC

Contact rating 250VAC, 5 A 30VDC, 5A

Breakdown voltage

Release time 10 ms max.

Operate time 10 ms max.

Contact resistance

Insulation resistance

Life expectancy

(min. operations)

Vibration Resistance

LED indicators

Power supply of Relay + 5V from the PCI-Bus

Table 1-2: Relay Output Specifications

1000 Vrms (open contacts), for 1 min

2000 Vrms (contacts and coil), for 1 min

1000MΩ min. (at 500 VDC)

> 5 X 107 times Mechanical

> 105 times Electrical

176.4m/s

Monitor Contact/Open status of each

relay; external LED connectors could be

10 mA rated

Up-to 24 VDC or 24V AC

Logic Low: 0~2V

Logic High: 5~24V

4.7 KΩ

30m

Ω

2

(18G), 10 to 55Hz at double
amplitude of 3mm

applied

4Introduction

Isolated +5V Power Supply

Output Voltage +5V

Output Current

Table 1-3: Power Supply Specifications

170mA max. (@ 40°C)

General Specifications

Dimension 174.7 mm x 106.7 mm, standard PCI half size

Bus 32-bit PCI bus

Operating temperature

Storage temperature

Humidity 5 to 85% non-condensing

Table 1-4: General Specifications

0°C ~ 60°C

-40

°C ~ 80°C

Power Consumption

PCI-7260

+5V @ 510 mA typical

990mA maximum when all relays are acting simultaneously

Table 1-5: Power Consumption Specifications

Introduction 5

1.4 Software Support

ADLINK provides versatile software drivers and packages for
users’ different approach to built-up a system. We provide not
only the programming library such as DLL for DOS and Windows,
but also drivers for many 3rd-party software packages. You may
find the programming library and 3rd-party software supports in
ADLINK All-in-One CD.

Programming Library

For customers who are writing their own programs with program­ming languages, we provide function libraries for different operat­ing systems, including:

DOS libaray

Function libarary for DOS based on Turbo C. Please refer to
chapter 5 for descriptions of functions.

PCIS-DASK

Device driver and libarary packge for Windows 98/NT/2000/XP.
The PCIS-DASK is binary compatible across Windows 98, NT,
2000 and XP. That means all applications developed with
PCIS-DASK can be migrated to any Windows OS. The devel­oping environment can be VB, VC++, Delphi, BC5, or any Win­dows programming language that allows DLL invokation. You
can find the driver package, user’s guide, and function refer­ence of PCIS-DASK are in ADLINK All-in-One CD. Please refer
to the manuals in x:\Manual\Software Package\PCIS-DASK\
for more information. (x: denotes your CD-ROM drive)

DAQ-LVIEW PnP

DAQ-LVIEW PnP is the “Plug & Play” VI set to interface with
National Instruments LabVIEW under Windows 98/NT/2000/XP.
The DAQ-LVIEW PnP is free of charge and included in ADLINK
All-in-One CD. Please refer to the manuals in x:\Manual\Software
Package\DAQ-LVIEW PnP\ for more information. (x: denotes your
CD-ROM drive)

6Introduction

2 Installation

This chapter outlines the contents of package, describes unpack­ing procedure, and describes how to install PCI-7260 into your
host system.

2.1 What you have

In addition to the User’s Manual, the package includes the follow­ing items:

X PCI-7260 non-latching relay and digital input cards

X ADLINK All-in-One CD

X This User’s Manual

If any of these items are missing or damaged, contact your
ADLINK dealer. Save the shipping materials and carton in to ship
or store the product in the future.

2.2 Unpacking

Your PCI-7260 card contains sensitive electronic components that
can be easily damaged by static electricity.

The card should be operated on a grounded anti-static mat. The
operator should be wearing an anti-static wristband, grounded at
the same point as the anti-static mat.

Inspect the card module carton for obvious damage. Shipping and
handling may cause damage to your module. Be sure there are no
shipping and handling damages on the module before processing.

After opening the card module carton, extract the system module
and place it only on a grounded antistatic surface with component
side up.

Again inspect the module for damage. Press down on all the
socketed IC's to make sure that they are properly seated. Do this
only with the module place on a firm flat surface.

Note: DO NOT APPLY POWER TO THE CARD IF IT HAS BEEN

Installation 7

DAMAGED.

You are now ready to install your PCI-7260.

2.3 PCB Layout

The location of connectors, DIP switches and jumpers are shown
in Figure 2.1. They are described in the following sections.

Figure 2-1: PCI-7260 PCB Layout

8Installation

2.4 AC/non-AC filter setting (JP1)

The PCI-7260 is a ‘plug and play’ add-on card for PCI bus. It is not
necessary for user to setup its base address and IRQ level to fit
the hardware of your computer system. However, to fit user’s ver­satile operation, there are still a few jumpers to set for the digital
input.

The JP1 on PCI-7260 card are used to configure the digital input
channels as AC-Filtered or Non-AC-Filtered inputs. AC-filter is
used to filter unexpected noise in the digital signal. Each digital
input channel and its corresponding jumper are shown in the fol­lowing Table2.1.

JUMPER INPUT SIGNAL

JP1 DI0 ~ DI7

Table 2-1: The jumpers and DI channels

The default setting of the input signal selection is Non-AC-Filtered
(DC signal input), which is shown as below :

Figure 2-2: Default Input Signal Jumper Setting

Installation 9

2.5 Isolated digital input connector (JP2)

DI 0+
DI 1+
DI 2+
DI 3+
DI 4+
DI 5+
DI 6+
DI 7+
GND
+5V

Figure 2-3: Isolated Digital Input Connector

The PCI-7260 card contains 8 opto-isolated digital input channels.
Utilizing the 20-pin ribbon connector (JP2) , users can connect
digital inputs to the isolated channels of PCI-7260.

Each row of JP2 corresponds to one of the eight DI channels. The
corresponding channel connection is shown in Figure 2.3. The dig­ital input channels are isolated by photo couplers and accept
0~24V input voltage. The logic high is 5~24V and the logic low is
0~2V.

JP2

1 2
3 4
5 6
7 8
9 10
11 12
13 14
15 16
17 18
19 20

DI 0­DI 1­DI 2­DI 3­DI 4­DI 5­DI 6­DI 7­GND
+5V

10 Installation