Automationdirect CTRIO Users guide

CTRIO

High-Speed Counter

Module

Manual Number: HX-CTRIO-M

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CTRIO HIgH-Speed COunTeR uSeR Manual

Please include the Manual Number and the Manual Issue, both shown below,
when communicating with Technical Support regarding this publication.

Manual Number: HX-CTRIO-M

Issue: 3rd Edition, Rev. E

Issue Date: 03/21

Publication History

Issue Date Description of Changes

First Edition 9/01 Original

Rev. A 10/01 Corrections

Rev. B 8/02 Corrections

Second Edition 2/03 Added T1H-CTRIO and H4-CTRIO. Updated for CTRIO/Workbench version 2.

Rev. A Added H0-CTRIO and flowcharts.

Rev. B 10/03 Corrections

Rev. C 03/11 Made corrections and updated manual.

Updated manual with new H0-CTRIO2 and H2-CTRIO2 information.

Rev. D 2/13

Rev. E 09/13

Third Edition 06/16 Completely reworked and reorganized manual.

Added Do-more PLC series data and examples.
Updated CTRIO Workbench section with new pulse profiles available.
Made minor corrections throughout manual.

Added Do-more structure table to Chapter 6.
Added Appendix A, Appendix B and Appendix C which contain flowcharts for various

instructions
Made minor corrections throughout manual.

Rev. A 11/18 Revised and added material to Appendix B.

Rev. B 6/19 Revised and added material to Chapter 9, pp 28-34.

Rev. C 10/19 Revised and added material to Chapter 1, pp 9, Chapter 2, pp 5.

Rev. D 08/20 T1H-PBC module retired; added notes to Ch1, Ch3, and Ch7 accordingly.

Rev. E 08/20 Revised ladder program B-14, B-15, B-16.

Table of ConTenTs

Chapter 1 - Introduction to the CTRIO & CTRIO2 Modules

Introduction ............................................................................................................... 1–2

Conventions Used ...................................................................................................... 1–3

CTRIO and CTRIO2 Module Overview ...................................................................... 1–4

Support Systems for the CTRIO(2) Modules ............................................................1–6

CTRIO(2) Specifications ............................................................................................. 1–7

H0-CTRIO(2) LED Indicators .................................................................................... 1–10

H2-CTRIO(2) LED Indicators .................................................................................... 1–11

H4-CTRIO LED Indicators .........................................................................................1–12

T1H-CTRIO LED Indicators.......................................................................................1–13

Overview, How it Works as Part of the Control System .........................................1–14

CTRIO(2) Module Work Flow Diagram ...................................................................1–17

Chapter 2 - Getting Started, Basics and Examples

Overview .................................................................................................................... 2-2

Basic Motion Functions, Summary of Examples ....................................................... 2-2

Detailed Example: Configure and Test a Quadrature Input ................................... 2-7

Detailed Example: Configure and Test a Pulse Output w/Trapezoidal Profile ..... 2-16

Flow Chart Example: Configure and Test a Pulse Output w/Trapezoidal Profile 2-27

Chapter 3 - Installation and Field Wiring

Installing the H0-CTRIO(2) Module .......................................................................... 3-2

Setting H0-CTRIO(2) Jumpers ................................................................................... 3-3

Table of Contents

H0- CTRIO(2) Quadrature Encoder Wiring Example ................................................ 3-5

H0-CTRIO(2) TTL Quadrature Encoder Field Wiring ............................................... 3-6

H0- CTRIO(2) TTL Input Wiring ................................................................................ 3-7

H0- CTRIO(2) Output Wiring Schematic ................................................................... 3-8

H0-CTRIO(2) Stepper/Servo Drive Wiring Example ................................................. 3-9

Solid State Input Device Wiring to the H0-CTRIO(2) Module ............................... 3-10

Installing the H2-CTRIO(2) Module ........................................................................ 3-11

Setting H2-CTRIO(2) Jumpers ................................................................................. 3-12

Wiring the H2-CTRIO(2) Module ............................................................................ 3-13

H2- CTRIO(2) Quadrature Encoder Wiring Example .............................................. 3-14

H2-CTRIO(2) TTL Quadrature Encoder Field Wiring .............................................. 3-15

H2-CTRIO(2) TTL Input Wiring ............................................................................... 3-16

H2- CTRIO(2) Output Wiring Schematic ................................................................. 3-17

H2-CTRIO(2) Stepper/Servo Drive Wiring Example ............................................... 3-18

Solid State Input Device Wiring to the H2-CTRIO(2) Module ............................... 3-19

Installing the H4-CTRIO ........................................................................................... 3-20

Wiring the H4-CTRIO Module ................................................................................. 3-21

H4-CTRIO Quadrature Encoder Wiring Example .................................................... 3-22

H4-CTRIO TTL Quadrature Encoder Field Wiring ................................................... 3-23

H4-CTRIO TTL Input Wiring .................................................................................... 3-24

H4-CTRIO Output Wiring Schematic ....................................................................... 3-25

H4-CTRIO Stepper/Servo Drive Wiring Example .................................................... 3-26

Solid State Input Device Wiring to the H4-CTRIO Module .................................... 3-27

Installing the T1H-CTRIO ......................................................................................... 3-28

Wiring the T1H-CTRIO Module ............................................................................... 3-29

T1H-CTRIO Quadrature Encoder Wiring Example .................................................. 3-31

T1H-CTRIO TTL Quadrature Encoder Field Wiring ................................................. 3-32

T1H-CTRIO TTL Input Wiring .................................................................................. 3-33

T1H-CTRIO Output Wiring Schematic..................................................................... 3-34

Counter I/O User Manual, 3rd Ed., Rev. E

ii

Table of Contents

T1H-CTRIO Stepper/Servo Drive Wiring Example .................................................. 3-35

Solid State Input Device Wiring to T1H-CTRIO Module ........................................ 3-36

Chapter 4 - CTRIO Workbench, Overview

Configuring a CTRIO Module for Do-more CPUs ..................................................... 4–2

What is CTRIO Workbench? ......................................................................................4–2

Getting Started with CTRIO Workbench ..................................................................4–3

Module Modes of Operation .....................................................................................4–6

Chapter 5 - CTRIO Workbench, Configuring Inputs

Configure I/O Dialog Overview ................................................................................5–2

Input Function Selections .......................................................................................... 5–3

Counter Function ....................................................................................................... 5–4

Pulse Catch ................................................................................................................5–6

Edge Timer ................................................................................................................. 5–7

Dual Edge Timer ........................................................................................................5–8

Reset FN1 and Reset FN2 (Hard Resets for Counters Only) ..................................5–10

Soft Resets ..............................................................................................................5–10

Capture FN1 ............................................................................................................. 5–11

Inhibit FN1 ............................................................................................................... 5–11

Limit Out .................................................................................................................. 5–11

Introduction to the Scaling Wizard ........................................................................5–12

Chapter 6 - CTRIO Workbench Configuring Outputs

Configure I/O Dialog Overview ................................................................................6–2

Output Function Selections ....................................................................................... 6–3

Raw Output ................................................................................................................ 6–4

Discrete Outputs ........................................................................................................ 6–5

Pulse Outputs ...........................................................................................................6–11

Counter I/O User Manual, 3rd Ed., Rev. E

iii

Table of Contents

Chapter 7 - CTRIO Workbench, I/O Map

I/O Map Dialog .......................................................................................................... 7–2

Chapter 8 - CTRIO Workbench, Monitor I/O

Using the Monitor I/O Dialog ................................................................................... 8–2

Monitor I/O Error Codes ........................................................................................... 8–7

Chapter 9 - Output Functions

Runtime Changes to CTRIO Configured Preset Tables (DL PLCs) ........................... 9–3

Pulse Output Profiles (DL PLCs) ................................................................................ 9–6

Trapezoid Profile........................................................................................................ 9–7

S-Curve Profile ........................................................................................................... 9–8

Symmetrical S-Curve Profile ...................................................................................... 9–9

Home Search Profile ................................................................................................ 9–10

Free Form Profile .....................................................................................................9–13

Pulse Output Status/Control Bits and Command Codes (DL PLCs) ......................9–14

DirectLOGIC Programming Examples Overview ....................................................9–20

Trapezoid with Limits Profile ..................................................................................9–21

Trapezoid with Limits (CTRIO2) Profile ..................................................................9–22

Pulse Output Status/Control Bits and Command Codes (DL PLCs) ......................9–25

Trapezoid Plus (CTRIO2) Profile ..............................................................................9–29

Pulse Output Status/Control Bits and Command Codes (DL PLCs) ......................9–31

Load and Run a Trapezoid Plus Profile .................................................................9–34

Dynamic Positioning Plus and Dynamic Positioning Profiles .................................9–35

Dynamic Positioning Plus (CTRIO2) Profile ............................................................ 9–36

Pulse Output Status/Control Bits and Command Codes (DL PLCs) ......................9–37

Dynamic Velocity Profile ..........................................................................................9–43

Pulse Output Status/Control Bits and Command Codes (DL PLCs) ......................9–44

Velocity Mode .........................................................................................................9–49

Pulse Output Status/Control Bits and Command Codes (DL PLCs) ......................9–50

Counter I/O User Manual, 3rd Ed., Rev. E

iv

Table of Contents

Run to Limit Mode .................................................................................................9–55

Pulse Output Status/Control Bits and Command Codes (DL PLCs) ......................9–56

Run to Position Mode .............................................................................................9–62

Pulse Output Status/Control Bits and Command Codes (DL PLCs) ......................9–63

Run to Position Mode with DirectSOFT IBox Instructions ..................................... 9–68

Raw Output .............................................................................................................. 9–70

Pulse Output Status/Control Bits and Command Codes (DL PLCs) ......................9–71

Chapter 10 - Input Functions

Input Memory Mapping for Counter Data Transfer ..............................................10–2

Input Memory Map for Scaled Counter Data .......................................................10–5

Input Memory Map for Capture Count Data Transfers .........................................10–9

Input Memory Map for Edge Timer and Dual Edge Timer .................................. 10–12

Input Memory Map for Pulse Catch Data Transfers .............................................10–25

Chapter 11 - Runtime Table Functions

Introduction to Runtime Table Functions ............................................................... 11–2

Preset Tables and Programmable Limit Switch (PLS) Tables ................................. 11–4

Load Preset Table .................................................................................................... 11–4

Load Table ................................................................................................................ 11–8

Clear Preset Table ................................................................................................. 11–11

Create Preset Table (Initialize Table) .................................................................... 11–14

Add Entry to Preset Table .....................................................................................11–17

CTRIO2 - DirectLOGIC Using IBoxes Flowcharts...................................................11–18

CTRIO2 - DirectLOGIC PLC Flowcharts .................................................................11–19

Edit Preset Table Entry .......................................................................................... 11–20

Edit Preset Table Entry and Reload ....................................................................... 11–23

Write File to ROM .................................................................................................. 11–26

Create Preset Table on Reset (Initialize Table on Reset) .....................................11–29

Update Level (Edit Level Response) ...................................................................... 11–32

Counter I/O User Manual, 3rd Ed., Rev. E

v

Table of Contents

Appendix A - Memory Mapping

Input Memory Map for Data Transfers from CTRIO(2) to DL CPUs ........................ A-2

Output Memory Map for Data Transfers from DL CPUs to CTRIO(2) ..................... A-4

Addressing Conventions (with V-memory Examples for DirectLOGIC PLCs) .......... A-7

Input Function Status/Control Bits and Parameters ................................................ A-8

Appendix B - System Functions

System Functions ....................................................................................................... B-2

Write All Registers (IBoxes) ....................................................................................... B-3

Write All Registers (DL-PLC)...................................................................................... B-4

Write One Register (IBoxes) ...................................................................................... B-5

Write One Register (DL-PLC) .................................................................................... B-6

Read All Registers (IBoxes) ........................................................................................ B-7

Read All Registers (DL-PLC) ...................................................................................... B-8

Read One Register (IBoxes) ...................................................................................... B-9

Read One Register (DL-PLC) ................................................................................... B-10

Read Error Code (IBoxes) ........................................................................................ B-11

Read Error Code (DL-PLC) ....................................................................................... B-12

System Functions Examples Overview .................................................................... B-13

Single Channel Simulating Retentive Quad Counter ............................................ B-14

Dual Channel Simulating Retentive Quad Counters .............................................. B-17

Reading CTRIO Internal Registers ........................................................................... B-20

Counter I/O User Manual, 3rd Ed., Rev. E

vi

IntroductIon to the
ctrIo & ctrIo2

Chapter

Chapter

Chapter

Modules

In This Chapter...

Introduction ............................................................................................................... 1–2

Conventions Used ...................................................................................................... 1–3

CTRIO and CTRIO2 Module Overview ...................................................................... 1–4

Support Systems for the CTRIO(2) Modules ............................................................1–6

CTRIO(2) Specifications ............................................................................................. 1–7

CH0-CTRIO(2) LED Indicators .................................................................................1–10

H2-CTRIO(2) LED Indicators .................................................................................... 1–11

H4-CTRIO LED Indicators .........................................................................................1–12

T1H-CTRIO LED Indicators.......................................................................................1–13

Overview, How it Works as Part of the Control System .........................................1–14

CTRIO(2) Module Work Flow Diagram ...................................................................1–17

1

1

1

Chapter 1: Introduction to the CTRIO & CTRIO2 Modules

Introduction

The Purpose of this Manual

This manual is intended as a help for the user to install, program, and maintain the CTRIO(2)
module in their system. This manual contains important information for personnel who
will install the CTRIO(2) high-speed counter module as well as for the PLC programmer.
This manual will provide all the information needed for the novice and seasoned automation
professional alike to start and keep your system up and running.

Online Help Files and Other Documentation

Regardless of the platform you are using, the programming software needed for the CTRIO(2)
modules is available as a download from our website.

http://www.aboutplcs.com/

Each programming software includes searchable online help topics covering all aspects of the
software, instruction set, module setup, and communications.

Technical Support

We strive to make our manuals the best in the industry. We rely on your feedback to let us
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or, if for any reason you need technical assistance, please call us at:

1-770–844–4200

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Monday through Friday from 9:00 A.M. to 6:00 P.M. Eastern Time. We also encourage you

to visit our web site where you can find information about our company and specific technical
information about a wide array of our products, www.automationdirect.com.

1–2

Counter I/O User Manual, 3rd Ed., Rev. E

Conventions Used



DL




DL

Win












NOTE: When you see the “note pad” icon in the left-hand margin, the paragraph to its immediate right will be
a special note. Notes represent information that may make your work quicker or more efficient. The word
NOTE in boldface will mark the beginning of the text.

WARNING! When you see the “exclamation point” icon in the left-hand margin, the paragraph to its
immediate right will be a warning. This information could prevent injury, loss of property, or even
death in extreme cases. Any warning in this manual should be regarded as critical information that
should be read in its entirety. The word WARNING in boldface will mark the beginning of the text.

Chapter 1: Introduction to the CTRIO & CTRIO2 Modules

Key Topics for Each Chapter

The beginning of each chapter will list the key topics that
can be found in that chapter.

Getting Started!

In This Chapter...

.............................................................................1-2

Introduction

About Getting Started!
Supplemental Manuals and Other Help

.............................................................................1-2

Technical Support

....................................................................1-3Conventions Used

CHAPTER

....................................................................1-2Purpose of this Manual

......................................................................1-2

............................................1-2

Icons

CTRIO(2) modules are available for several hardware platforms, including DL05/06,
DL205, DL405 and Terminator. Among these four hardware platforms, there are a variety
of CPUs that can occupy the CPU slot, including, Do-more, DirectLOGIC or WinPLC.
There are also several communication interface modules that could occupy the
CPU slot, including EBCs, Modbus, DeviceNet or Profibus.

Throughout this manual, a set of icons (on right) is used to designate which
hardware platform a topic applies to, based on what module is in the CPU slot.

Icon Legend:

Do-more icon- Topic is applicable when CTRIO(2) is used with a Do-more CPU or

DM

in a slave on a Do-more CPU’s Ethernet I/O network.

DirectLOGIC icon- Topic is applicable when CTRIO(2) is used with a DirectLOGIC

DL

CPU.

WinPLC icon- Topic is applicable when CTRIO(2) is used with a WinPLC CPU.

Win

Network Interface icon- Topic is applicable when CTRIO(2) is used with any of the

NI

network interfaces: EBC (see Do-more icon instead if EBC is a slave on Do-more
Ethernet I/O network) DeviceNet, Profibus or Modbus.

1

DM

DL

Win

NI

Counter I/O User Manual, 3rd Ed., Rev. E.

1–3

Chapter 1: Introduction to the CTRIO & CTRIO2 Modules

CTRIO and CTRIO2 Module Overview

A CTRIO(2) module is a programmable motion co-processor capable of accepting a variety
of encoder or discrete sensor inputs, accepting commands from the CPU, natively executing
simple control algorithms, and generating a variety of pulse-type motion control signals or
discrete actuator outputs. A CTRIO can be used for a wide variety of basic motion tasks.
Most commonly, a CTRIO module is
used to:

• Track an encoder

• Calculate rate from an encoder

• Execute homing routines

• Generate simple motion profiles

• Send pulse train control signals
to a stepper or servo amplifier

• Precisely fire a discrete output based on the position read from an encoder

NOTE: The T1H-CTRIO(2) is only supported by the T1H-EBC, T1H-EBC100 and T1H-PBC (Retired 08/20).

H0-CTRIO(2)

Available Functions

The various functions available in a CTRIO(2) module are enumerated in the following text.
There are however, limitations and dependencies to keep in mind.

• An H0-CTRIO(2) module has 4 input points on its single channel. The H2-CTRIO(2)
modules have 8 input points split between two channels. Although each channel of a
CTRIO(2) module has four input points, a channel may have only two counters/quad
counters defined. The counter/quad counter inputs appear as Function 1 and Function 2
in CTRIO Workbench.

• Some functions rely on another function being enabled. For example, scaling
cannot be selected until other inputs have been configured as a counter
or quad counter. The dependencies are enforced by CTRIO Workbench
software to ensure that an invalid configuration cannot be created.

H2-CTRIO(2)

H4-CTRIO

T1H-CTRIO(2)

1–4

If a function cannot be found in CTRIO Workbench, try enabling the function(s) on which it might
depend.

Inputs:
Input types accepted:

• Quadrature encoder with AB or ABZ

• Counter (tachometer)

• Discrete (photo eye, limit switch, Z pulse, etc.)

Counter I/O User Manual, 3rd Ed., Rev. E

Chapter 1: Introduction to the CTRIO & CTRIO2 Modules

Functions available for discrete inputs:

• Pulse catch (high-speed discrete input with programmable filter)

• Timing: edge timer (period), dual edge timer (time difference of two inputs)

• Reset counts (Z input from encoder)

• Capture counts (copy counts of one of the counter inputs to a register)

• Inhibit counting (freeze one of the counter inputs)

• Limit for pulse output functions (CTRIO2, home switch on an axis)

Scaling of timing functions or encoder inputs:

• Rate scaling (allows the CTRIO(2) to provide encoder
data to the PLC in engineering units)

• Position scaling (allows the CTRIO(2) to provide encoder
data to the PLC in engineering units)

Outputs:
Assign the output points:

• Stepper control: Step/Direction or CW/CCW

• Discrete

Pulse profiles for stepper outputs to follow:

• Dynamic Position Plus, Trapezoid Plus, Trapezoid with Limits (homing)

(CTRIO2 only and CTRIO, Workbench v2.2.0 or later required)

• Trapezoid, S-curve, Symmetrical S-curve, Dynamic Position, Dynamic Velocity

• Home Search, Free Form

Associate output functions with inputs

• Programmable Limit Switch or ‘PLS’ (CTRIO2 only and
CTRIO Workbench v2.2.0 or later required)

• Preset tables.

Unsuitable Applications

There are some applications the CTRIO(2) specifications appear to support that are not
feasible. Common applications a CTRIO(2) cannot readily handle are listed below. If in
doubt regarding your application, please contact Automationdirect Tech Support for assistance.

Closed loop control: CTRIO2 modules are capable of very basic closed loop control. However, they

do not have full functionality expected of a typical dedicated closed loop controller. Most notably,
position or velocity errors are not reported and there is no built-in error alarming.

• CTRIO modules do not support any closed loop control. Trying to use the CPU to
close the control loop will produce unacceptable results due to excessive latency.

Counter I/O User Manual, 3rd Ed., Rev. E.

1–5

Chapter 1: Introduction to the CTRIO & CTRIO2 Modules

Coordinated motion: Some CTRIO(2) modules have enough outputs to control multiple axes,

but there is no internal mechanism to coordinate them. Axes can move simultaneously, but
not with coordination.

Follower: CTRIO(2) modules cannot support follower applications natively. Trying to use

the CPU to close the control loop will produce unacceptable results due to excessive latency.

Precise registration: There is no means for precisely timing the start of a motion profile. Motion

profiles are initiated by the controller in the base, so scan time latency of the controller is

always a factor.
Absolute encoders: A CTRIO(2) module cannot read an absolute encoder.
Mechanical contacts as counter or encoder inputs: Reliable readings are not possible using

mechanical contacts. The bounce of mechanical contacts will cause the CTRIO(2) to see

more edges than intended.
Direct connection to TTL, line driver or differential encoders: A CTRIO(2) module cannot

accept these low voltage inputs directly. These signals need to be level shifted as shown in

Chapter 3: Installation and Field Wiring.

Support Systems for the CTRIO(2) Modules

The CTRIO(2) modules are compatible with several CPU-slot interfaces. Consideration
must be given to the firmware versions of the CPU-slot interfaces to assure their compatibility
with the CTRIO(2) (See Chapter 3 for CPU/CTRIO compatibility listings). Multiple
CTRIO(2) modules can reside in the same base provided that the backplane power budget is
adequate.

1–6

Support Systems for the H0-CTRIO(2):

• DirectLOGIC 05/06 PLC systems

Support Systems for the H2-CTRIO(2):

• DirectLOGIC 205 PLC systems (D2-240, D2-250-1, D2-260, D2-262)

• DL205 WinPLC systems (H2-WPLCx-xx)

• PC-based control strategies using the H2-EBC(100) interface module

• Hx-ERM networks using the H2-EBC(100) interface module

• Profibus systems using the H2-PBC slave interface module

• Do-more PLC systems (H2-DM1, H2-DM1E); See Do-more Designer help file.

• Do-more PLC Ethernet I/O network using H2-EBC100;
See Do-more Designer help file.

Counter I/O User Manual, 3rd Ed., Rev. E

Chapter 1: Introduction to the CTRIO & CTRIO2 Modules

Support Systems for the H4-CTRIO:

• DirectLOGIC 405 PLC systems (D4-450 OR D4-454 only)

• PC-based control strategies using the H4-EBC interface module

• Hx-ERM networks using the H4-EBC interface module

Support Systems for the T1H-CTRIO:

• PC-based control strategies using the T1H-EBC interface module

• Profibus systems using the T1H-PBC slave interface module (Discontinued 08/2020)

• Hx-ERM networks using the T1H-EBC interface module

• Do-more PLC Ethernet I/O network using T1H-EBC100

CTRIO(2) Specifications

The tables following show general and specific information associated with CTRIO modules.

Module
Module Type
Modules Per Base

I/O Points Used

Field Wiring
Connector

Internal Power
Consumption

Operating
Environment

Manufacturer

Isolation

H0-CTRIO H0-CTRIO2 H2-CTRIO H2-CTRIO2 H4-CTRIO T1H-CTRIO

None, I/O map directly in PLC memory (V-memory for DirectLOGIC PLCs and Data structures for Do-more

250mA at +5V from Base

Power Supply

(All I/O in ON State at Max

Voltage/Current)

32°F to 140°F (0°C to 60°C), Humidity (non-condensing) 5% to 95%

2500V I/O to
Logic, 1000V
among Input
Channels and

All Outputs

1500V I/O to

Logic, 1000V

among Input

Channels and

All Outputs

General

Intelligent

Limited only by power consumption

PLCs) or PC control access

Standard removable terminal block

400mA Max at +5V

from Base Power

Supply
(All I/O in ON State at
Max Voltage/Current)

Host Automation Products, LLC

2500V I/O to Logic,
1000V among Input

Channels and All

Outputs

275mA Max at +5V

from Base Power

(All I/O in ON State at
Max Voltage/Current)

1500V I/O to Logic,

1000V among Input

Channels and All

Supply

Outputs

400mA Max at +5V from

Base Power Supply

(All I/O in ON State at Max

Voltage/Current)

2500V I/O to Logic, 1000V

among Input Channels and

All Outputs

Counter I/O User Manual, 3rd Ed., Rev. E.

1–7

Chapter 1: Introduction to the CTRIO & CTRIO2 Modules

CTRIO(2) Specifications, cont’d

CTRIO(2) Input Specifications

Module

Inputs

Minimum Pulse Width
Input Voltage Range
Maximum Voltage
Input Voltage Protection
Rated Input Current
Minimum ON Voltage
Maximum OFF Voltage
Minimum ON Current
Maximum OFF Current

OFF to ON Response

ON to OFF Response

Counter/Timer

Resource Options

Timer Range/ Resolution

Counter Range

H0-CTRIO H0-CTRIO2 H2-CTRIO H2-CTRIO2 H4-CTRIO T1H-CTRIO

4 pts. sink/

source

100kHz Max

5 µsec 0.5 µsec 5 µsec 0.5 µsec 5 µsec

Less than 3

µsec

2, (2 per single 4 input
channel); supports 1
quadrature counter max.

1X, 2X, or 4X Quadrature, Up or Down Counter, Edge Timer, Dual Edge Timer, Input Pulse Catch,
Reset, Inhibit, Capture

4 pts. sink/

source 250kHz

Max

5.0 mA (9VDC required to guarantee ON state)

Less than 0.5

µsec

4.2 billion (32 bits); 1 µsec (70 minutes)

W2.1 billion (32 bits or 31 bits + sign bit)

8 pts. sink/source

100kHz Max

9-30 VDC

30VDC

Zener Clamped at 33VDC

8mA typical, 12mA maximum

9.0 VDC

2.0 VDC

2.0 mA

Less than 3 µsec Less than 0.5 µsec Less than 3 µsec

4, (2 per each 4 input channel group); supports 2 quadrature

8 pts. sink/source

250kHz Max

counters max.

8 pts. sink/source

100kHz Max

Module

Pulse output / Discrete
outputs

Resource Options

Target Position Range

Counter I/O User Manual, 3rd Ed., Rev. E

1–8

CTRIO(2) Output Resources

H0-CTRIO H0-CTRIO2 H2-CTRIO H2-CTRIO2 H4-CTRIO T1H-CTRIO

Pulse outputs: 1 channel (2
outputs per single channel)
Discrete outputs: 2 pts.

Pulse Outputs: pulse/direction or cw/ccw; Profiles:Trapezoid, S-Curve, Symmetrical S-Curve,
Dynamic Positioning, Dynamic Velocity, Home Search, Free Form, Dynamic Positioning Plus (CTRIO2
only),Trapezoid Plus (CTRIO2 only), Trapezoid w/Limits (CTRIO2 only), Velocity Mode, Run to Limit
Mode, Run to Position Mode
Discrete Outputs: configurable for set, reset, pulse on, pulse off, toggle, reset count functions
(assigned to respond to Timer/Count input functions).
Raw Mode: Direct access to discrete outputs from user application program

W2.1 billion (32 bits or 31 bits + sign bit)

Pulse outputs: 2 channels (2 outputs per each channel)
Discrete outputs: 4 pts.

Chapter 1: Introduction to the CTRIO & CTRIO2 Modules

CTRIO(2) Specifications, cont’d

CTRIO(2) Output Specifications

Module

Outputs

Pulse Output Control
Range
Voltage Range

Maximum Voltage
Output clamp voltage

Maximum load current

Maximum load voltage
Maximum leakage

current
Inrush current

OFF to ON response
ON to OFF Response
ON state V drop
External power supply

Overcurrent protection

Thermal shutdown
Overtemperature reset

Duty cycle range
Configurable Presets

a) single
b) multiple

H0-CTRIO H0-CTRIO2 H2-CTRIO H2-CTRIO2 H4-CTRIO T1H-CTRIO

2 pts, isolated, either both current

sourcing or both current sinking

FET Outputs: open drain and

source with floating gate drive

20Hz to 25kHz 20Hz to 250kHz 20Hz to 25kHz 20Hz to 250kHz 20Hz to 25kHz

1.0A

36VDC 33VDC 36VDC 36VDC 36VDC

5A for 20ms 1A for 10ms 5A for 20ms 2A for 10ms 5A for 20ms

15A max

a) Each output can be assigned one preset, or
b) Each output can be assigned one table of presets, one table can contain max. 128 presets,

max. predefined tables = 255

0.5 A at 23°C

0.33 A at 60°C

Less than 3 µsec Less than 1 µsec Less than 3 µsec

m 0.3 V m 0.45 V m 0.3 V

For loop power only, not required for internal module function*

15A max;

Self resetting

overcurrent

protection

1% to 99% in 1% increments (default = 50%)

4 pts, independently isolated, current sourcing or sinking

FET Outputs: open drain and source with floating gate drive

5VDC – 36VDC

36VDC
60VDC

1.0 A

100µA

Tjunction = 150°C

Tjunction = 130°C

1.0 A at 23°C,

0.5 A at 60°C

15A max

1.0 A

Counter I/O User Manual, 3rd Ed., Rev. E.

1–9

Chapter 1: Introduction to the CTRIO & CTRIO2 Modules

H0-CTRIO(2) LED Indicators

H0-CTRIO(2) LED Descriptions

OK

ERR

A
B

Y0 - Y1

LED Status

OK ERR

ON OFF RUN Mode

ON ON Hardware Failure

Blinking Blinking Boot Mode - Used for Field OS Upgrades

Blinking OFF Program Mode

OFF Blinking Module Self-diagnostic Failure

OFF ON Module Error Due to Watchdog Timeout

OFF OFF No Power to Module

Module OK

User Program Error

Ch1 F1 Resource State

Ch1 F2 Resource State

Output Status

H0-CTRIO(2) LED Diagnostics

Status Description

1–10

H0-CTRIO(2) LED Run Diagnostics Definitions

A
B

Y0–Y1

Blinks when Channel 1 Function 1 is counting or timing

Blinks when Channel 1 Function 2 is counting or timing

Follow actual output state; ON = output is passing current

Counter I/O User Manual, 3rd Ed., Rev. E

Chapter 1: Introduction to the CTRIO & CTRIO2 Modules

H2-CTRIO(2) LED Indicators

H2-CTRIO(2) LED Descriptions

OK
ER

1A
2A

0–3

LED Status

OK ER

ON OFF RUN Mode

ON ON

Blinking Blinking Boot Mode - Used for Field OS Upgrades

Blinking OFF Program Mode

Module OK

User Program Error

Channel 1 Status

Channel 2 Status

Output Status

H2-CTRIO(2) LED Diagnostics

Hardware Failure (H2-CTRIO)

Not Used (H2-CTRIO2)

Status Description

OFF Blinking Module Self-diagnostic Failure (Blinks may be coded by counts)

OFF ON Module Error Due to Watchdog Timeout

OFF OFF No Power to Module

H2-CTRIO(2) LED Diagnostics Definitions

1A /2A

Blinking 7 times per second Input is Configured as Counter and is Changing

Following State of Input Input is not Configured as Counter

0–3

Follow actual output state; ON = output is passing current

Counter I/O User Manual, 3rd Ed., Rev. E.

1–11

Chapter 1: Introduction to the CTRIO & CTRIO2 Modules

H4-CTRIO LED Indicators

H4-CTRIO LED Descriptions

OK

ER

TB
1A–1D
2A–2D

(Ch1) F1–F2
(Ch2) F1–F2

Y0–Y3

LED Status

OK ER

ON OFF RUN Mode

Blinking Blinking Boot Mode - Used for Field OS Upgrades

Blinking OFF Program Mode

OFF Blinking Module Self-diagnostic Failure

OFF ON Module Error Due to Watchdog Timeout

OFF OFF No Power to Module

Module OK

User Program Error

Removed Terminal Block

Ch1A - Ch1D Input Status

Ch2A - Ch2D Input Status

Ch1 Resource State

Ch2 Resource State

Output Status

TB

H4-CTRIO LED Diagnostics

Status Description

User Terminal Block is not Properly Installed

1–12

H4-CTRIO LED Diagnostics Definition

1A–1D

2A–2D
(Ch1) F1
(Ch1) F2
(Ch2) F1
(Ch2) F2

Y0–Y3

NOTE: Due to the multiplexed design of the DL405 LED matrix, OFF state LEDs may appear to blink ON
slightly. This is to be expected and does not necessarily indicate a transient condition of the function
corresponding to the LED.

Follow actual input state / Ch1

Follow actual input state / Ch2

Blinks when Channel 1 Function 1 is counting or timing

Blinks when Channel 1 Function 2 is counting or timing

Blinks when Channel 2 Function 1 is counting or timing

Blinks when Channel 2 Function 2 is counting or timing

Follow actual output state; ON = output is passing current

Counter I/O User Manual, 3rd Ed., Rev. E

Chapter 1: Introduction to the CTRIO & CTRIO2 Modules

T1H-CTRIO LED Indicators

T1H-CTRIO LED Descriptions

OK
ERR
CH1
CH2

1A–1D
2A–2D

Y0–Y3

LED Status

OK ER

ON OFF RUN Mode

ON ON Hardware Failure

Blinking Blinking Boot Mode - Used for Field OS Upgrades

Blinking OFF Program Mode

OFF Blinking Module Self-diagnostic Failure

OFF ON Module Error Due to Watchdog Timeout

OFF OFF No Power to Module

Module OK

User Program Error

Channel 1 Status

Channel 2 Status

Channel 1 A-D Input Status

Channel 2 A-D Input Status

Output Status

T1H-CTRIO LED Diagnostics

Status Description

CH1

CH2
1A–1D
2A–2D

Y0–Y3

T1H-CTRIO LED Diagnostics Definitions

Blinks when Channel 1 Function 1 is counting or timing

Blinks when Channel 2 Function 1 is counting or timing

Follow actual input state / Ch1

Follow actual input state / Ch2

Follow actual output state; ON = output is passing current

Counter I/O User Manual, 3rd Ed., Rev. E.

1–13

Chapter 1: Introduction to the CTRIO & CTRIO2 Modules

Overview, How it Works as Part of the Control System

Basic Operation

A CTRIO(2) is an intelligent co-processor module. It has to be configured using CTRIO
Workbench before it can do anything. It has its own scan time and can be in either program
or run mode.

Being an Intelligent Module means that the CTRIO(2) controls its own writes to and reads
from CPU memory. The CPU does not directly write to or read from the CTRIO(2). The
CTRIO(2) will write to and read from the addresses designated in I/O Map. Understanding this
relationship is helpful to understanding the timing (interlocking) requirements for performing
operations that require the PLC to make changes to the CTRIO(2) from ladder logic.

Understand that the CPU can only make requests to the CTRIO(2) by turning on specific bits
and placing appropriate data in its own memory. The CTRIO(2) reads the data from those
addresses in the CPU and then acts on it. The CTRIO(2) provides feedback to the CPU by
writing to other CPU memory.

NOTE: A CTRIO(2) is an Intelligent Module. It directly writes to and reads from CPU memory. The CPU
cannot directly write to or read from CTRIO(2) memory. The CTRIO(2) writes to and reads from the
addresses designated in I/O Map.

After being configured by CTRIO Workbench, a CTRIO(2) module is ready to be placed in
run mode. Basic input functions of the CTRIO(2) run automatically, such as reporting counts
on an input channel. Output functions are initiated by the controller (the PLC CPU). The
controller uses Command Codes to control the output functions of the CTRIO(2), such as
executing a pulse profile on an output, or loading or editing a preset table. IBox instructions
are macros that use Command Codes. Command Codes and the instructions on their use are
found later in this manual.

1–14

Counter I/O User Manual, 3rd Ed., Rev. E

Chapter 1: Introduction to the CTRIO & CTRIO2 Modules

CTRIO Workbench

CTRIO Workbench is the utility used to configure the many functions available for a
CTRIO(2) module.

CTRIO Workbench communicates with a CTRIO(2) module through the base controller to
configure the CTRIO(2). The configuration is stored in the CTRIO(2) and also stored in a
file on your computer. Configuring the CTRIO(2) is a separate process from programming
the base controller.

The CTRIO Workbench
configuration contains these basic
parameters:

• Assignments of the input and
output points

• Scaling of inputs (optional)

• Preset Table setup (optional)

• Programmable Limit Switch setup
(CTRIO(2), optional)

• Mapping to CPU memory

NOTE: The CTRIO(2) must be configured in program mode, and the memory must be mapped prior to
program execution.

Counter I/O User Manual, 3rd Ed., Rev. E.

1–15

Chapter 1: Introduction to the CTRIO & CTRIO2 Modules

Command Codes

Command Codes are the instructions available to the CPU to tell the CTRIO what to do. A list
of the Command Codes with a brief description of their function are shown in the table below.

Command Code and Parameter Definitions

Command

Load Table from ROM 10

Load Table from ROM 10

Load Table from ROM 10

Velocity Mode 20

Run to Limit Mode 21

Run to Position Mode 22

* A value of 0 will generate a duty cycle of 50%

Code

(Hex/BCD)

Those fields separated by an “&” indicate a code with different definitions for each byte
(high byte and low byte). For example, to enter the Pulse Output to Limit command, set the
high byte of the Word Parameter 2 to the edge you wish to terminate the output pulses (see
definition following), and set the low byte to the desired duty cycle.

In order to process a command, first the program must load the Command Code and required
DWord, Word, and bit parameters. Then the program should turn ON the Process Command
bit and look for the CTRIO(2) module to acknowledge the command with the Command
Complete bit. Finally, the program should reset the Process Command bit and set the Enable
Output bit when appropriate. If the Command Error bit is received, the CTRIO(2) module
was unable to process the command due to an illegal value in either the Command Code or
parameter files.

DWord and Word values for pulse outputs are unsigned integers (Parameter 3 on some profiles
can be signed).

Word Parameter 1

(decimal)

Trapezoid or S-curve

Symmetrical S-Curve

Home Search

File Number

Dynamic Positioning

File Number

Dynamic Velocity

File Number

Run Frequency

(CTRIO: 20Hz - 25KHz

CTRIO2: 20Hz - 64KHz)

Run Frequency

(CTRIO: 20Hz - 25KHz

CTRIO2: 20Hz - 64KHz)

Run Frequency

(CTRIO: 20Hz - 25KHz

CTRIO2: 20Hz - 64KHz)

Word Parameter 2 DWord Parameter 3

- -

- Target Position (decimal)

- Target Velocity (decimal)

Duty Cycle (0 to 99)*

(decimal)

Edge &

Duty Cycle (0 to 99)*

(Hex/BCD)

Compare Function &

Duty Cycle (0 to 99)*

(Hex/BCD)

Number of Pulses (BCD/Hex)

-

Desired Input Function Value

(decimal)

1–16

Counter I/O User Manual, 3rd Ed., Rev. E

Chapter 1: Introduction to the CTRIO & CTRIO2 Modules

CTRIO(2) Module Work Flow Diagram

The following workflow diagram shows the steps needed, with their associated chapters in this
manual, to install and setup a CTRIO(2) module into your system.

DirectLOGIC, WinPLC or EBC

Install CTRIO

Chapter 3

Configure CTRIO using

CTRIO Workbench

Chapter 4, 5 & 6

Testing Wiring using
CTRIO Workbench’s

Monitor I/O Dialog

Chapter 7, 8 & 9

Map Memory

in Controller

Chapter 10, Appx A

Runtime Table Functions

Chapter 11

System Functions

Appendix B

Counter I/O User Manual, 3rd Ed., Rev. E.

1–17

Chapter

Chapter

GettinG Started,
BaSicS and exampleS

In This Chapter...

Overview .................................................................................................................... 2-2

Basic Motion Functions, Summary of Examples ....................................................... 2-2

Detailed Example: Configure and Test a Quadrature Input ................................... 2-7

Detailed Example: Configure and Test a Pulse Output w/Trapezoidal Profile ..... 2-16

Flow Chart Example: Configure and Test a Pulse Output w/Trapezoidal Profile 2-27

Chapter

2

2

2

Chapter 2: Getting Started

Overview

This chapter is intended for the newcomer and includes brief descriptions of how to implement
some common motion control solutions using CTRIO(2). The descriptions should give the
newcomer a good understanding of what basic steps are required to implement the function.
With this general understanding, specifics on each step can be sought out later in the manual.

Later in the chapter, two detailed examples walk the user through what is required to implement
two of the most common functions, reading a quadrature encoder and generating a trapezoidal
profile.

Basic Motion Functions, Summary of Examples

Get Position Using an Encoder

To read the position of an encoder, follow these basic steps in CTRIO Workbench:

1: Config I/O - Configure the appropriate inputs to recognize the encoder.
2: Optionally set up position scaling if desired.
3: Use I/O Map to map the CTRIO(2) to the controller’s memory and print the I/O Map

Report.
4: Download the configuration to the CTRIO(2) module and put the CTRIO(2) in Run.
5: Finally, go online with the controller to check that the encoder counts are appearing in

the mapped address.

2-2

Get Rate Using an Encoder

To read the rate of an encoder, follow these basic steps in CTRIO Workbench:

1: Select Config I/O under Module Configuration to Configure the appropriate inputs to

recognize the encoder.
2: Set scaling to rate - Scaling Wizard ruler button:
3: Choose the conversion parameters.
4: Use the Rate Scaling Calculator to verify the chosen settings.
5: Use I/O Map to map the CTRIO(2) to the controller’s memory and print the I/O Map

Report.
6: Download the configuration to the CTRIO(2) module and put the CTRIO(2) in Run.
7: Go online with the controller to check that encoder rate is appearing in the mapped

address.

Measure Timing Between Pulse Edges

To measure the time between edges of a pulse in CTRIO Workbench:

1: Select Config I/O under Module Configuration to configure an input as Edge Timer,

selecting the appropriate options (free-run is suggested for testing since it does not

require interaction from the controller to function).
2: Optionally, set up scaling if desired.

Counter I/O User Manual, 3rd Ed., Rev. E