GPIO4D User Guide
8/2/12
Overview
-10 to +10 VDC current or velocity requests. The GPIO4D combines the functions of a PLC and third party
drive interface to reduce system component count and increase value.
The GPIO4D allows MPU11 based control systems to interface to third party servo drives that accept
GPIO4D Features
Application: Third Party Drive Interface
Number of Axes: 4
Axis DAC Resolution: 16 bits
Axis Analog Output Voltage: -10 to +10 Volts
Spindle DAC Resolution: 12 bits
Spindle Analog Output Voltage: 0 to +10 Volts
General Purpose Digital Inputs: 16
General Purpose Digital Outputs: 16
Control Interface: 2 fiber optics to MPU11
motion control card
Dimensions (W*D*H): 12 * 5 * 0.75 inches
GPIO4D Connection Overview
The GPIO4D communicates with an MPU11 motion control card through two optical fibers. The PLC
protocol fibers (1 and 3) handle communication of drive interface signals as well as general purpose I/O.
Encoder feedback returns directly to the MPU11.
svn://software/hardware/GPIO4D/080916/docs/GPIO4D_MAN.doc MRR Page 1 of 11
GPIO4D Outputs
Sixteen general purpose relay outputs and four axis enable outputs are available on the GPIO4D. Four
axis brake outputs and a fault output are also provided, but are not part of the PLC I/O space. The brake outputs
follow the state of their axis enables. The fault output will remain closed as long as the GPIO4D does not detect
any serious errors, such as a loss of communication.
Internal Circuitry
Relay Outputs
H1
COM
NO
OUT7
OUT8
OUT9
Relay outputs on H2 are functionally equivalent
COM
NO
NC
COM
NO
NC
Pin 20
svn://software/hardware/GPIO4D/080916/docs/GPIO4D_MAN.doc MRR Page 2 of 11
Motor Brake and Enable Outputs
Each axis has brake and enable outputs, which are functionally equivalent. These open collector outputs
may be used to drive a relay to release axis brake solenoids or activate an enable input on a servo drive. Note
that the GPIO4D has no noise suppression on the outputs. Appropriate suppression must be added to devices
connected to the open collector outputs. Typically, a DC relay coil is driven by a brake output and a diode is
placed across the coil leads to suppress voltage transients, as in the wiring example. Motor brake mechanisms
may also require noise suppression, such as a resistor and capacitor network for AC solenoids or a diode for DC
solenoids.
Internal Circuitry
Enable and Brake Relay Driver Outputs
H14
Pin 1
OUT17
OUT17
5V
COMMON
Outputs on H11, H12, and H13 are functionally equivalent
EN
BRK
OUTCOM
Typical Brake Wiring Example
External Power Supply
5 VDC
5 COM
External Power Supply
24 VDC
24 COM
Brake Release
Solenoid
svn://software/hardware/GPIO4D/080916/docs/GPIO4D_MAN.doc MRR Page 3 of 11
Analog Outputs
Five analog outputs are provided by the GPIO4D. Four analog outputs are used to request motion from
servo drives. These motion request outputs have 16 bit resolution and a fixed output range of -10V to +10V.
Motion request analog channels are digitally trimmed at the factory. The remaining analog output is used to
request a spindle speed from an inverter. The spindle analog output has 12 bit resolution and an output range
from 0 to 10V. Minor adjustment can be made to the spindle analog output range using the “OFFSET”
potentiometer (pot) (VR4) and “GAIN” pot (VR2). Only adjust the “OFFSET” pot at the minimum possible
spindle speed. This adjustment is intended only to null the voltage level when 0 RPM is commanded. The
“GAIN” pot should be used at maximum speed to match actual RPM with commanded RPM. Adjustments to
the analog output should be very minor and cannot be used to compensate for incorrect inverter or control
settings. VR1 and VR3 pots should not be used. If VR1 has been turned, measure from TP11 to analog
common and adjust the voltage back to 2.5V. If VR3 has been turned, measure from TP13 to analog common
and adjust the voltage back to 5.0V.
Internal Circuitry
Axis Analog Output
Internal Circuitry
Spindle Analog Output
+12 VDC
-
+
-12 VDC
SPINDLE ANALOG
SPINDLE ANALOG
COMMON
12 V
COMMON
H6
Pin 12
+12 VDC
H14
-
+
-12 VDC
12 V
COMMON
Axis analog outputs on H11, H12, and H13 are functionally equivalent
AN
ANCOM
Pin 1
svn://software/hardware/GPIO4D/080916/docs/GPIO4D_MAN.doc MRR Page 4 of 11
GPIO4D Inputs
four. Each bank is configurable for various voltages and sinking or sourcing polarity. Voltage may be selected
by installing the appropriate value resistor pack or SIP into a socket for each bank. Polarity is determined by
wiring the common terminal for the bank to the supply positive or supply common.
The GPIO4D has 16 general purpose inputs and 4 drive fault inputs. Inputs are divided into banks of
Sinking (NPN) Sensor Wiring Example
External Power Supply
+24 VDC
+24 VDC
+24 COM
GPIO4D Inputs
Sensor
+24 COM
Sourcing (PNP) Sensor Wiring Example
External Power Supply
+24 VDC
+24 COM
+24 VDC
Sensor
+24 COM
Pin 1
H9
COM 13-16
IN16
IN15
IN14
IN13
COM 9-12
IN12
IN11
IN10
IN9
SIP1
SIP2
I/O bank 5-8 and 1-4 on H10 are functionally equivalent to 15-16 and 9-12
.
svn://software/hardware/GPIO4D/080916/docs/GPIO4D_MAN.doc MRR Page 5 of 11
Typical Fault Input Wiring Example
5
12
24
Servo Drive Internal Circuitry
Fault or Alarm Relay
24 VDC
24 COM
SIP Identification - XXX Indicates Value
GPIO4D Fault Inputs
H14
FLTCOM to H13
FLTCOM to H12
FLTCOM to H11
FLTCOM
FLT (IN 17)
FLT (IN 18) to H13
FLT (IN 19) to H12
Pin 1
FLT (IN 18) to H11
SIP5
SIP Internal Wiring / Pinout
4308R-102
-XXX
SIP Input Voltage Selection
SIP Value Marking Resistor Value (Ohms) Input Voltage
471
102
222
470
1.0k
2.2k
svn://software/hardware/GPIO4D/080916/docs/GPIO4D_MAN.doc MRR Page 6 of 11
PLC Expansion
PLC I/O expansion is possible through the four “PLC ADD” connectors. Each PLC expansion port can
accept 16 – 128 inputs, outputs, or inputs and outputs in 16 bit increments. This allows for digital I/O, DACs,
ADCs, or other devices to be added to the system as needed.
PLC ADD 1 – 4 Connector Pinouts
DATA TO PLC +
CLOCK +
+12V
+5V
5V RETURN *
1 2
3 4
5 6
7 8
9 10
11 12
DATA TO EXPANSION CARD -DATA TO EXPANSION CARD +
DATA TO PLC CLOCK -
-12V
+12V AND -12V RETURN *
5V RETURN *
* +12V AND -12V RETURN and 5V RETURN are connected on the GPIO4D
PLC I/O is arranged in 16 bit groups or slots. As a general rule, slots 0-14 are used for individual I/Os
such as switches and have a programmable debounce time for the inputs. Slots 15-47 are reserved for ADCs,
DACs, or other devices that do not require debounce. Every device using I/O space must use space in 16 bit
multiples by reserving slots. PLC expansion boards with inputs and outputs must have a matching number of
input and output slots.
A GPIO4D uses 2 slots for its inputs and 7 slots for outputs. Since I/O space must be reserved in 16 bit
increments, some I/O space is lost. For example, the GPIO4D has 20 inputs which reserve 2 slots or 32 inputs,
leaving 12 inputs unused. Also note that the GPIO4D outputs are not assigned contiguously. The individual
outputs take slots 0-1, while the DACs are assigned to the group output area starting at slot 15.
Assignment of I/O slots occurs sequentially starting at the main PLC, then PLC ADD port 1, PLC ADD
port 2, etc. In the “GPIO4D I/O Organization” example, GPIO4D I/O will always be at the same location since
local PLC resources are assigned slots first. Other devices may change locations if they are plugged into PLC
ADD ports in a different order. Devices plugged into the PLC ADD ports that require debounce will be
assigned starting at the slots marked “A”, while devices that do not require debounce will start being assigned at
the slots marked “B”.
GPIO4D I/O Organization
svn://software/hardware/GPIO4D/080916/docs/GPIO4D_MAN.doc MRR Page 7 of 11
GPIO4D I/O Map
Input Map
Output Map
Input Specification Input Location
Number Function Type Connector Pin
1 General Purpose
2 General Purpose
3 General Purpose
4 General Purpose
5 General Purpose
6 General Purpose
7 General Purpose
8 General Purpose
9 General Purpose
10 General Purpose
11 General Purpose
12 General Purpose
13 General Purpose
14 General Purpose
15 General Purpose
16 General Purpose
17 Drive Fault 1
18 Drive Fault 2
19 Drive Fault 3
20 Drive Fault 4
241-256 Axis 1 Analog 16 bit DAC H14 1
257-272 Axis 2 Analog 16 bit DAC H13 1
Configurable
Configurable
Configurable
Configurable
Configurable
Configurable
Configurable
Configurable
Configurable
Configurable
Configurable
Configurable
Configurable
Configurable
Configurable
Configurable
Configurable
Configurable
Configurable
Configurable
H10 1
H10 2
H10 3
H10 4
H10 6
H10 7
H10 8
H10 9
H9 1
H9 2
H9 3
H9 4
H9 6
H9 7
H9 8
H9 9
H14 3
H13 3
H12 3
H11 3
*Note: Outputs 17-20 each control two physical outputs
Number Function Type Connector Pin
273-288 Axis 3 Analog 16 bit DAC H12 1
289-304 Axis 4 Analog 16 bit DAC H11 1
305-316 Spindle Analog 12 bit DAC H6 11
317-320 Reserved
1 General Purpose Relay SPST H1 1,2
2 General Purpose Relay SPST H1 3,4
3 General Purpose Relay SPST H1 5,6
4 General Purpose Relay SPST H1 7,8
5 General Purpose Relay SPST H1 9,10
6 General Purpose Relay SPST H1 11,12
7 General Purpose Relay SPST H1 13,14
8 General Purpose Relay SPDT H1 15,16,17
9 General Purpose Relay SPDT H1 18,19,20
10 General Purpose Relay SPST H1 1,2
11 General Purpose Relay SPST H1 3,4
12 General Purpose Relay SPST H1 5,6
13 General Purpose Relay SPST H1 7,8
14 General Purpose Relay SPST H1 9,10
15 General Purpose Relay SPST H1 11,12
16 General Purpose Relay SPST H1 13,14
17 Drive Enable 1 Open Collector H14 5
18 Drive Enable 2 Open Collector H13 5
19 Drive Enable 3 Open Collector H12 5
20 Drive Enable 4 Open Collector H11 5
17 Axis 1 Brake Open Collector H14 6
18 Axis 2 Brake Open Collector H13 6
19 Axis 3 Brake Open Collector H12 6
20 Axis 4 Brake Open Collector H11 6
Fault Relay SPDT H2 15,16,17
Output Specification Output Location
svn://software/hardware/GPIO4D/080916/docs/GPIO4D_MAN.doc MRR Page 8 of 11
GPIO4D Specifications
Characteristic Min. Typ. Max. Unit
5 Volt Supply Current 1.4 - - A
12 Volt Supply Current 0.09 - - A
-12 Volt Supply Current 0.07 - - A
Input Pullup Voltage (Vinp) 4.5 5 25 V
Input On Voltage Vinp-1.25 - - V
Input Off Voltage - - 1.25 V
Input Operating current 9 11 15 mA
Relay Output Current 0.1 - 10 A @ 125VAC
Relay Output Current 0.1 - 5 A @ 30VDC
Open Collector Output Current - 10 90 mA
Open Collector Output Voltage - 5 25 V
Spindle Analog Output Resolution - 12 - bits
Spindle Analog Output Voltage 0 - 10 V
Spindle Analog Output Current 0 1 10 mA
Axis Analog Output Resolution - 16 - bits
Axis Analog Output Voltage -10 - 10 V
Axis Analog Output Current 0 1 10 mA
PLC ADD Port 5V Current Output* 0 - 1 A
PLC ADD Port 12V Current Output* 0 - 0.8 A
PLC ADD Port -12V Current Output* 0 - 0.8 A
Fiber 1 and 3 Length - - 100 feet
Size: 12 * 5 * 0.75 (W*D*H) Inches
*PLC ADD Port Current is a total for all 4 ports in any combination. The power supply
may be the limiting factor; make sure it can handle the GPIO4D current ratings in addition
to the PLC Expansion board requirements.
GPIO4D Troubleshooting
Symptom Possible Cause Corrective Action
PLC OK LED out Motion control card hasn't booted up Start software, wait for the main screen to load
Fibers 1 or 3 connected incorrectly or
All status LEDs out Logic power not applied Measure AC coming into power supply, correct
5V, +12V, or -12V LED out Power supply or connection problem Measure AC coming into power supply, correct
3.3V LED out, 5V LED lit Internal Problem Return for repair
Input doesn't work with
sensor
Voltage drop across sensor is too high Use 3-wire sensors with lower voltage drop spec.
faulty
Incorrect wiring Correct wiring for sensor type (sinking or
Check connections one at a time, swap with a
known good set of fibers
wiring or supply problems
wiring or supply problems
sourcing), check that SIP values are appropriate
for the input voltage
svn://software/hardware/GPIO4D/080916/docs/GPIO4D_MAN.doc MRR Page 9 of 11
Fault NC
Fault NO
Fault COM
Output 16 NO
Output 16 COM
Output 15 NO
Output 15 COM
Output 14 NO
Output 14 COM
Output 13 NO
Output 13 COM
Output 12 NO
Output 12 COM
Output 11 NO
Output 11 COM
Output 10 NO
Output 10 COM
Fiber 3 to MPU11
Fiber 1 from MPU11
Output 9 NC
Output 9 NO
Output 9 COM
Output 8 NC
Output 8 NO
Output 8 COM
Output 7 NO
Output 7 COM
Output 6 NO
Output 6 COM
Output 5 NO
Output 5 COM
Output 4 NO
Output 4 COM
Output 3 NO
Output 3 COM
Output 2 NO
Output 2 COM
Output 1 NO
Output 1 COM
Pin 1
Pin 1
GPIO4D Connections
+12V
12V Common
-12V
5V Common
5V
5V
3.3V
PLC OK
Spindle Analog
Analog Common
-12V
+12V
Enable
LED 1
Enable
LED 2
Enable
LED 3
Enable
LED 4
SIP5
SIP4
SIP3
SIP2
SIP1
Pin 1
Pin 1
Pin 1
Pin 1
Pin 1
Axis Analog 1
Analog Common
Fault Input Axis 1 (Input 17)
Fault Common
Enable Output Axis 1 (Output 17)
Brake Output 1 (Output 17)
Output Common
Axis Analog 2
Analog Common
Fault Input Axis 2 (Input 18)
Fault Common
Enable Output Axis 2 (Output 18)
Brake Output 2 (Output 18)
Output Common
Axis Analog 3
Analog Common
Fault Input Axis 3 (Input 19)
Fault Common
Enable Output Axis 3 (Output 19)
Brake Output 3 (Output 19)
Output Common
Axis Analog 4
Analog Common
Fault Input Axis 3 (Input 20)
Fault Common
Enable Output Axis 4 (Output 20)
Brake Output 4 (Output 20)
Output Common
Input 1
Input 2
Input 3
Input 4
Common 1-4
Input 5
Input 6
Input 7
Input 8
Common 5-8
Input 9
Input 10
Input 11
Input 12
Common 9-12
Input 13
Input 14
Input 15
Input 16
Common 13-16
PLC
PLC
Expansion 1
PLC
Expansion 2
Expansion 3
PLC
Expansion 4
svn://software/hardware/GPIO4D/080916/docs/GPIO4D_MAN.doc MRR Page 10 of 11
GPIO4D Mounting Dimensions
5.0"
(127mm)
4.4"
(112mm)
12.0"
(305mm)
11.4"
(290mm)
(152mm)
6.0"
svn://software/hardware/GPIO4D/080916/docs/GPIO4D_MAN.doc MRR Page 11 of 11
Loading...