ADD4AD4DA User Guide
MPU11
Fiber 1
Fiber 3
Fiber 1
Fiber 3
PLC ADD 1
PLC ADD 2
PLC ADD 3
PLC ADD 4
*Host PLC may be
GPIO4D, DC3IOB, etc.
I/O to PLC
Host PLC
ADD4AD4DA
Updated 3/29/10
Overview
The ADD4AD4DA is a PLC expansion board used to add analog inputs and outputs to a compatible
host PLC. The ADD4AD4DA has 4 analog outputs and 4 analog inputs.
ADD4AD4DA Features
Application: PLC Expansion Board
Analog Inputs: 4
Input Resolution: 12 bits
Analog Outputs: 4
Output Resolution: 16 bits
Control Interface: Shielded, twisted pair cable to host PLC
Update Rate: 2000 Hz
Dimensions (W*D*H): 9.8 * 3 * 0.6 inches
ADD4AD4DA Connection Overview
The ADD4AD4DA communicates with a host PLC through a cable connection to an expansion port.
The host PLC may have up to 16 PLC expansion ports, labeled “PLC ADD 1” through “PLC ADD 16”. The
ADD4AD4DA may connect to any available expansion port.
ADD4AD4DA User Guide Page 1 of 6
Analog Outputs
DAC Request
65536
*output voltage = 10 output voltage =
DAC Request
65536
*
( )
- 1020
0 to 10V Range -10 to 10V Range
DAC Request
65536
*output voltage = 5
0 to 5V Range -5 to 5V Range
output voltage =
DAC Request
65536
*
( )
-10 5
Four voltage output ranges are available on each analog output. Each analog output has a block of five
DIP switches that must be set according to the following chart to get the desired output range.
Analog Output Range Selection
Voltage
Range
0 TO 5 OFF ON ON ON ON
0 TO 10 OFF ON OFF ON OFF
-5 TO 5 ON ON OFF ON OFF
-10 TO 10 ON OFF OFF OFF OFF
1 2 3 4 5
Switch Number
Analog Output Calculations
Analog outputs use a 16 bit digital to analog converter (DAC) to generate analog from the DAC request
sent from the PLC program. The 16 bit value allows a DAC request of 0 to 65535, which corresponds to 0 to
9.9998 volts in the 0 to 10V range.
Analog Output Wiring
Analog outputs should be wired using a shielded twisted pair for best results. Each analog output
terminal is paired with a common terminal for direct wiring of the signal, common, and shield. In most cases, it
is best to connect the shield to the common only at the ADD4AD4DA. Routing analog cables away from power
wires and other noise sources is also critical for good performance. See “ADD4AD4DA Connections and
Mounting Dimensions” section for terminal locations.
Analog Output Trim
Analog outputs are factory trimmed for the 0 to 10V scale. If a different output range is used, it will be
necessary to trim the output for best results. The following procedure is used to trim the analog outputs:
1. Request 0V
2. Adjust offset POT until 0V is output
3. Request maximum output
4. Adjust gain POT until maximum is output (depends on range)
5. Repeat steps 1-4 until readings are consistent and correct
ADD4AD4DA User Guide Page 2 of 6
Analog Inputs
(
4096 * Input Voltage
5
4096 * Input Voltage
10
4096 * Input Voltage
+ 2048
)
10
(
4096 * Input Voltage
+ 2048
)
20
0 to 5V Range
0 to 10V Range -10 to 10V Range
-5 to 5V Range
ADC result =
ADC result =
ADC result =
ADC result =
Like the analog outputs, the inputs have four ranges available. Set the corresponding block of five DIP
switches according to the following chart to accept the required input range.
Analog Input Range Selection
Voltage
Range
0 TO 5 OFF OFF OFF X X
0 TO 10 OFF ON OFF X X
-5 TO 5 ON ON OFF X X
-10 TO 10 ON ON ON X X
1 2 3 4 5
Switch Number
X = don’t care
Analog Input Calculations
Analog inputs use a 12 bit analog to digital converter (ADC) to generate a digital ADC result for the
PLC from an analog signal. The 12 bit result allows an ADC result of 0 to 4095, which corresponds to 0 to
9.9975 volts in the 0 to 10V range.
is paired with a common terminal for direct wiring of the signal, common, and shield. In most cases, it is best
to connect the shield to the common only at the ADD4AD4DA. Routing analog cables away from power wires
and other noise sources is also critical for good performance. See “ADD4AD4DA Connections and Mounting
Dimensions” section for terminal locations.
necessary to trim the input for best results. The following procedure is used to trim the analog inputs:
Analog Input Wiring
Analog inputs should be wired using a shielded twisted pair for best results. Each analog input terminal
Analog Input Trim
Analog inputs are factory trimmed for the 0 to 10V scale. If a different input range is used, it will be
1. Input 0V in bipolar modes, or slightly above 0V in unipolar modes
2. Adjust offset POT until the reported voltage matches the actual voltage
3. Input a voltage slightly below the maximum (depends on range)
4. Adjust gain POT until the reported voltage matches the actual voltage
5. Repeat steps 1-4 until readings are consistent and correct
ADD4AD4DA User Guide Page 3 of 6
PLC Communication
12V RETURN
DATA TO EXPANSION CARD +
5V RETURN
1 2
3 4
5 6
7 8
9 10
11 12
13 14
15 16
DATA TO EXPANSION CARD -
+5V
+12V
5V RETURN
DATA TO PLC -DATA TO PLC +
CLOCK -
-12V
CLOCK +
J3
Pin 1
J4 J5
J5J3
Pin 1
J4
Communication with the host PLC is performed through H2 “I/O TO PLC” connector. See the host
PLC’s documentation to determine where I/O from the ADD4AD4DA will be located. ADD4AD4DA requires
four slots of input and output space in the group I/O section (slots 15-47). Communication update rate is 2000
times per second or once every 500us. Total update time will be longer based on PLC program scan time and
analog filtering. With a standard PLC stage (50 times / second), analog inputs will report correct voltage in less
than 50ms, and analog outputs will update in less than 30ms.
I/O TO PLC Connector (H2) Pinout
ADD4AD4DA Power
The ADD4AD4DA may operate from the host PLC’s +5, +12, and -12 VDC through the “I/O TO PLC”
connector H2. However, care must be taken not to overload the power supply when adding expansion boards to
a PLC. Refer to the specifications for each device and the power supply to make sure the supply can handle the
addition of the ADD4AD4DA.
If the host PLC’s supply can not support powering the ADD4AD4DA, jumper J3, J4, and J5 may be
changed to use power from header H4. This setting allows another power supply to be used to provide +5, +12,
and -12 VDC to the ADD4AD4DA.
Jumper Setting to Use Host PLC Power from H2 Jumper Setting to Use External +5V from H4
Number Function Type Connector Pin Number Function Type Connector Pin
1-12 General Purpose Analog H3 8 1-16 General Purpose Analog H1 1
13-16 Forced to 0 - - - 17-32 General Purpose Analog H1 3
17-28 General Purpose Analog H3 6 33-48 General Purpose Analog H1 5
29-32 Forced to 0 - - - 49-64 General Purpose Analog H1 7
33-44 General Purpose Analog H3 3
44-48 Forced to 0 - - -
49-60 General Purpose Analog H3 1
61-64 Forced to 0 - - -
ADD4AD4DA User Guide Page 4 of 6
ADD4AD4DA I/O Map
Input Map Output Map
Input Specification Input Location Output Specification Output Location
ADD4AD4DA Troubleshooting
Symptom Possible Cause Corrective Action
+5V, +12V, or -12V LED
out
Power supply overloaded If several expansion boards are powered from one
Power source set incorrectly Set J3, J4, and J5 to get power from H2 or H4 as
appropriate
supply, the current demands could be too much.
Add or change power supplies to provide at least
as much current as the expansion board ratings
call out.
PLC OK LED out, +5V
LED lit
Faulty cable to main PLC Check or replace cable connnected to H2 "I/O to
Host PLC Offline Troubleshoot host PLC
PLC" header
ADD4AD4DA Specifications
Characteristic Min. Typ. Max. Unit
5 Volt Supply Voltage 4.5 5 5.5 V
12 Volt Supply Voltage 11.5 12 12.5 V
-12 Volt Supply Voltage -12.5 -12 -11.5 V
5 Volt Supply Current 0.2 - - A
12 Volt Supply Current 0.15 - - A
-12 Volt Supply Current 0.15 - - A
Analog Output Current 0 1 10 mA
Analog Output Voltage -10 - 10 V
Analog Output Resolution - 16 - bits
Analog Output Error - < 0.1 - %
Analog Input Current - - 1 mA
Analog Input Voltage -10 - 10 V
Analog Input Resolution - 12 - bits
Analog Input Error - < 0.1 - %
Size: 9.8 * 3 * 0.6 (W*D*H) Inches
ADD4AD4DA User Guide Page 5 of 6
ADD4AD4DA Connections and Mounting Dimensions
I/O TO PLC
-12
ADC 4
SETTINGS
GAIN
Pin 1
Output 3
DAC 2
SETTINGS
OFFSET
ADCCOM1
(61 mm)
+5
Output 4
DAC 1
SETTINGS
OFFSET
Input 4
Input 3
DAC 3
SETTINGS
GAIN
3.0"
NC
J3
4.6"
DAC 4
SETTINGS
GAIN
DACCOM1
OFFSET
OFFSET
+12
Pin 1
GAIN
Input 2
J4
ADCCOM4
9.8"
ADCCOM3
GAIN
J5
OFFSET
2.4"
NC
(234 mm)
Output 1
OFFSET
EXTERNAL
POWER
H2
POWER
SOURCE
(249 mm)
DACCOM4
GAIN
ADC
INPUTS
H4
(76 mm)
NC
PLC OK
DAC
OUTPUTS
H3
NC
+12V
Output 2
ADCCOM2
ADC 1
SETTINGS
H1
Pin 1
GAIN
DACCOM2
5V COM
ADC 2
SETTINGS
DACCOM3
OFFSET
9.2"
NC
+5V
ADC 3
SETTINGS
12V COM
OFFSET
NC
(117 mm)
5V COM
+5V
-12V
GAIN
Input 1
ADD4AD4DA User Guide Page 6 of 6
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