Dutec I/O Plexer Hardware User Manual

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I/O PLEXER Nov. 23, 2004

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 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.

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Table of Contents

Overview ....................................................1 - 1

Capacity: ............................................1 - 1

I/O Signal Compatibility ................................1 - 2

Built-in Diagnostics: ....................................1 - 2

Easy Setup: ...........................................1 - 3

Protocol Compatibility ..................................1 - 3

Available I/O Functionality: ......................................1 - 4

Analog Inputs .........................................1 - 4

Analog Outputs........................................1 - 4

Digital Inputs .........................................1 - 5

Digital Outputs ........................................1 - 5

Extended capabilities: ...................................1 - 6

Communications watchdogs ..............................1 - 6

Specifications .................................................1 - 7

Communications.......................................1 - 7

Power ...............................................1 - 8

Environment ..........................................1 - 8

Package..............................................1 - 8

Ordering Information ...........................................1 - 8

Options ..............................................1 - 8

Available I/O Modules ..........................................1 - 9

Installation ...................................................1 - 1

Mounting: ............................................2 - 1

Power Wiring: ........................................2 - 1

Digital Expander.......................................2 - 2

Designing the network ..........................................2 - 3

Multidrop ............................................2 - 5

Repeat............................................... 2 - 5

Network Type Switches .........................................2 - 6

Repeat ..............................................2 - 7

Multidrop ............................................2 - 7

Last Unit.............................................2 - 7

Communications Wiring ........................................2 - 8

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Table of Contents

RS-232 Host to I/O Plexer wiring .........................2 - 8

Modem to I/O Plexer - RS-232 ...........................2 - 9

RS-422 Host to I/O Plexer wiring ........................2 - 10

Host to I/O Plexer- RS-485 .............................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 - 14

Module Wiring ...............................................2 - 15

Analog Inputs: .......................................2 - 15

Analog outputs: ......................................2 - 17

Digital Inputs: ........................................ 2 - 18

Chassis Setup .................................................2 - 1

Baud rate ....................................... 3 - 1, 3 - 3

Setup pushbutton ......................................3 - 1

Sequential display...................................... 3 - 1

Protocol handshake types ................................3 - 3

Modem Jumpers .......................................3 - 3

Changing setup parameters ......................................3 - 4

Equivalent RS-232/ 422 Communications circuit ..................... A-1

I/O Performance ............................................... A-1

Instruction Format ............................................. B-1

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Introduction 1

Overview

I/OPLEXERs 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 more 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.

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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 conditioning is required. Furthermore, all duTec modules feature total electrical isolation, both module-tologic, 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.

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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 communications 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 E1 1 E2 2 E3 3

Expander Digital I/O function address

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.

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Introduction 1

Available I/O Functionality:

Analog Inputs

Input Value Determines signal levels, with 12 bits resolution*

Offsets Input values can be software offset, with 12 bits resolution,

over the module’s specified range.

Gain/ Slope The amplitude of input values can be software multiplied by

factors ranging from 0.25 to 4.0.

Range Limits The occurrence of input values falling out of user defined

upper or lower limits can be flagged.

Minimums The minimum level input values can be captured.

Maximums The maximum level input values can be captured.

Averages Can calculate average input amplitude for 1-65,535 samples.

Temperature Can linearize in °C, inputs from thermocouples and RTD’s.

Will also return temperature probe data.

Analog Outputs

Level Value Can set output levels, as a fraction of the module’s full scale

range, and are specified with 12 bits resolution.

Waveforms 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

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Introduction 1

Digital Inputs

Read Read the ON or OFF state of all inputs.

Pulse widths 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 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 1-256on a system wide basis.

Pulse Counting 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.

Edge Detection Off-to-On and On-to-Off transitions can be detected within

1 msec of their occurrence. Action is only reported each 10 msec.

Note: 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

Set outputs Can set individual or multiple outputs ON or OFF.

Modifiers One Shot 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.

Delayed 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.

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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 Generator 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-all 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.

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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.

Maximum Distance

Serial Link Feet Meters

RS-232 50 15

RS-422 5,000 1,524

RS-485 5,000 1,524

Modem Unlimited 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.

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Introduction 1

Physical Characteristics:

Power Standard 85-132Vac@30W (47-440Hz)

Option E, E5 105-256 Vac @23W/ 39W

(47-440Hz) Option /B 10-16 VDC@35W Option/C 18-36 Vdc @35W

Environment Temperature 0° -60°C

Humidity 95% non-Condensing

Package Type Stainless Steel

Length 17.25 in. (44 cm) Width 5.0 in (12.7cm) Height (w/ modules) 3.5 in. (8.9cm) Weight 4 Pounds (1.8Kg)

Options /L Local Control Functions

/3+ Expansion ports for 3 digital

expanders

Ordering Information

Specify duTec products by model number:

IOP-AD I/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.

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Introduction 1

Frequency IF10K-B Input 300Hz-10Khz OV1 Output 0-1V, self sourcing IF2.5K-L Input 0-2.5Khz 0v5 Output 0-10V, self sourcing IF5K-L Input 0-5Khz 0v10 output 0-10V, self sourcing IF10K-L Input 0-10 KHz

Voltage IV25M Input 0-25mV 01420 Output, 4-20mA Self-Sourcing IV50M Input 0-50mV into 275 Ohm Load. IV100M Input, 0-100mV IV1 input 0-1V IV5 Input 0-5 V AC IV5B Input bi-polar ±5V IAC5 Input 90-140Vac IV10 Input 0-10V IAC5A Input 180-280Vac IV10B Input Bi-polar ±10V DC IVAC Input 28-140 Vac IDC5D Input 3-32 VDC fast>500Hz IVAC-A Input 56-280 Vac IDC5NP Input 10-32 Vdc, 15-32

Current II420 Input 4-20 mAdc IIAC5 Input 0-5Aac AC

Thermocouple ITCE Type E 0° to 435°C OAC5 Output 12-140 Vac, 3.5A ITCJ Type J 0° to 700°C OAC5A Output 24-280Vac, 3.5A ITCJ-1 Type J -80° to 750°C OAC5A5 Output 24-280Vac 3.5A NC ITCK Type K -100° to 924°C ITCK-1 Type K -110° to 1250° C OAC5J Output 20-280Vac, 6.0A ITCR Type R 0° to 960° C DC

ITCR-1 Type R 0° to 1760° C ODC5 Output 5-60 Vdc, 3.5A ITCS Type S 0° to 1034° C ODC5A Output 4-200Dc, 1.0A ITCS-1 Type S 0° to 1760°C ODC5R Electro-Mechanical 0.5A Relay Form

ITCT Type T -200° to 224° C ITCT-1 Type T -120° to 400° C IDC5S* Dry input contact sense, built in

ITCT-2 Type T 0° to 150° C isolated source

RTD ITR100 100 Ohm PT -50° to 350°C IDC5Z* Input±200mV, 0-10Khz ITR100-1 100 Ohm PT 0° to 100°C (digital)**

Type 590

ITP590 -188.4° to 150°C TIO1 Digital Input/output Test Module ITP590-1 -50.0° to 150°C with field switch and LED

* When Selecting A power supply for the system, assume 25mA for standard digital Fuses

modules and 100mA for modules marked FMP-06 Fuse Assy 0.062A

With an * FMP-1 Fuse Assy, 1A

** The IDC5ZModule is used for low-level FMP-3 Fuse Assy, 3A

signals and wil

10Khz The I/O

Communicatio

Analog inputs, 12 Bit Analog Outputs, 12 Bit

Temperature Sensor SPS-1* Sensor power supply 18-24Vdc,

l pass signals at the rate of Plexer however is limited by ns baudrate.

Available I/O Modules

Voltage

Current

Digital Inputs

Nonpolar

Digital Outputs

A NO

Special Purpose

30mA

Support Products

FMP-5 Fuse Assy 5A

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Notes:

Introduction 1

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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 4 #6-32 Screws

5.0

3.5

.375

16.5

17.25

Slot Mounting 2 #10-24 Screws

2.25

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.

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Installation 2

AC Wiring DC Wiring

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 /E5 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

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Installation 2

Designing the network

In order for the I/O PLEXER to share its data 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; RS232 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

I/O P

LEXER

Temperature

Strip Chart

Outputs

HOST

P. C.

Lamp

Meter

Level Switch

larm

Inputs

Dial

Serial

Link

Figure 2-3 Typical installation

Multiple I/O PLEXER Master chassis can be networked together to service large numbers of I/O Points.

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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. 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 RS232 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.

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Installation 2

Once the physical network media has been chosen, a decision as to which units, if any will play an active roll in signal 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.

Figure 2-4 I/O Plexer Network Types

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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.

Figure 2-5 Connectors, Switches, and Indicators

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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.

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Installation 2

Communications Wiring

Host to I/O PLEXER - RS-232

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.

When distances greater than 50 feet are encountered the Host must be equipped with

an RS-422/ 485 device

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Installation 2

Modem to I/O Plexer - RS-232

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 Clear 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.

2 - 9

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Installation 2

Host to I/O Plexer - RS-422

Figure 2-11 RS-422 Host to I/O Plexer wiring

The wiring figure shows two individually shielded 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 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 50-579005, 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 “pullup” in figure 2-5

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. An alternative

Installation 2

Host to I/O Plexer- RS-485

Figure 2-12 RS-485 Host 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.

. An alternative

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

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2 - 11

Installation 2

I/O Plexer to I/O Plexer - RS-422

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.

. 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 50-579005, and used pins, 16-02-0103

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2 - 12

Installation 2

I/O Plexer to I/O plexer - RS-485

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 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.

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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).

Figure 2-15 Digital Expanders

Digital expanders are configured during the main chassis’ normal setup procedure (see section 3)

2 - 14

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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

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 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

On brightly, off, or flicker otherwise.

Figure 2-16 AC current and voltage wiring

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Installation 2

Figure 2-17 Analog Frequency, Voltage, and current input wiring

igure 2-18 Temperature input wiring

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Installation 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.

Figure 2-19 Analog Voltage and current output wiring

OI420 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

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Installation 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 IDC5S 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 IDC5D 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, IAC5A, or the IDC5S 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.

Figure 2-20 Digital Input Wiring

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Installation 2

Digital outputs:

Modules should never be installed or removed while power is applied to the I/O PLEXER.

ODC5, ODC5A, OAC5, and OAC5A digital output modules are used to switch external power supply loads on and off.

Because they contain a protective reverse diode, the ODC5 and ODC5A 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 OAC5A 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.

Figure 2-21 Digital output Wiring

2 - 19

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Notes:

Installation 2

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Setup 3

Chassis Setup

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

3 - 1

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Setup 3

Function Abbrev. Function

Address

Master Unit control MC 00

Master unit digital I/O MD 40

Master Unit Analog I/O*** MA 80

Digital Expander D1 C0H (192)

Digital expander D2 D0H (208)

Digital expander D3 E0H (224)

H (0)

H (64)

H (128)

Sequential Display

U0=00

U1=40

U2=80

U3=00

U4=d0

U5=E0

The OFFSET addressing 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 00 D1=C3

H, D2=D3H, D3=E3H.

H to 03H will automatically cause MD=43H, MA=83H,

Variable Mode

In the VARIABLE mode function addresses are independent of each other and can range from 00

H 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 34

*** Any function address not supported by the unit will default to the master unit control address to conserve network address usage.

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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 instruction 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)

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3 - 3

Setup 3

Changing setup 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 nonvolatile EEPROM.

During the diagnostic test period following the application of power, the sequential display shows GoGoGo= 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 U0 indicates the master unit control address; initially set for address 00H -00. Note: In the address offset mode, only the master unit address is set, The

other addresses are automatically set 40 3-2).

. Flashing the pushbutton LED once when

H above each other (see page

The 3 digits after 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 -

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.

3 - 4

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Setup 3

The unit is now in the operational mode and the sequential display cycle becomes*:

U0=00

U1=40

U2=80

U3=C0

U4=d0

U5=E0

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 in this example

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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 I/O 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 any. 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

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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.

3 - 7

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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 exchange. 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.

3 - 8

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Appendix A

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.

A-1

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Notes:

Appendix A

A-2

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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 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.

Baud Output (Digital

Rate 1 Ch/ IOP 16 Ch/ IOP 1 Ch/ IOP 16 Ch/ IOP

mSec/

chan

300 501 2 501 32 379 3 379 42

600 251 4 251 64 195 5 195 82

1200 126 8 126 127 104 10 104 154

2400 64 16 64 252 58 17 58 277

4800 32 31 32 496 35 29 35 458

9600 17 60 17 962 23 43 23 682

19200 9 113 9 1816 18 56 18 902

38400 5 203 5 3261 15 67 15 1076

chan/Sec mSec/

16 chan

chan/

Input (Digital M)

mSec/

Sec

chan

chan/Sec mSec/

16 chan

chan/

Sec

B-1

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Appendix B

Baud Input (analog L) Output (analog S)

Rate 1 Ch/ IOP 16 Ch/ IOP 1 Ch/ IOP 16 Ch/ IOP

mSec/

Chan/ Sec mSec/

Chan

300 639 2 2639 6 484 2 1984 8

600 323 3 1323 12 250 4 1000 16

1200 164 6 664 24 134 7 509 31

2400 85 12 335 48 75 13 263 61

4800 46 22 171 94 46 22 140 114

9600 26 39 88 181 32 32 78 204

19200 16 63 47 339 24 41 48 335

38400 11 91 27 602 21 48 32 494

Chan

Chan/

Sec

mSec/C

han

Chan/ Sec mSec/

16 Chan

Chan / Sec

B-2

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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.

Figure B-1 Digital Input Data Time for 1-16 Channels:

Figure B-2 Digital Output Execution

1-16 Channels

Throughput for analog I/O varies with the number of channels, n

Figure B-3 Analog Input Data Time for n Channels

Figure B-4 Analog Output Execution

The system throughput for systems with a mixture of analog and digital data is determined

by the sum of the time for each instruction using these equations.

n Channels

B-3

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Notes:

Appendix B

B-4

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Instruction Format

Appendix C

return

||||| |||||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 |

NN C ( ) ( ) All instructions terminate with a carriage

Response format (2 pass communications protocol)

A ( ) ( ) All responses terminate with a carriage return | | | | | |Checksum if data field present | | | |Data field depends on function and instruction type | |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 >AUA ( ) A Yes B Reset >AU C Turn-around Delay >LUCf

F Identify type >AU

G Configure analog VS

B ( ) A Yes

( ) A Yes

F ( ) Az ( ) Yes

( ) A Yes

>MCGc

digital G Configure all modules >IOGe H Configure as inputs >IOHe

I Configure as outputs >IOIe

j Read module

( ) A Yes

( ) Ac ( ) Yes

>Ioj

configuration

v Read chassis ID >MC

Y Read firmware version >MC

c Set network baudrate

E Protocol -2 Pass

-4 Pass

7 >MCch ( ) Ah ( ) NO

7 >LUEO ( ) A Yes

7 >LUE1 ( ) A Yes

v ( ) AS ( ) NO Y ( ) A$ ( ) NO

C-1

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Appendix C

Function Instruction Response OPTO22 Equiv.

Watchdog

m Pos/Delay -Digital >DDmcn ( ) A Yes D Pos/ Delay -Analog >MADcg m Pos/ Levels -Analog >MAmc...1 cD WDM Del

>MCeD

( ) A Yes

( ) A NO

multiplier*256 dD -Disable >McdD cJ WDM Del

( ) A NO

>IOeD

multiplier*256 dJ -Disable >IOdD n TRM, Timer Res

( ) A NO

( ) A Yes

>DDny

Multiplier cA Address Tag -Enable >MCeA dA -Disable >MCdA eC Chk sum tag -Enable >MCeC dC -Disable >MCdC eE Error Msgs -Off >MCeE dE -On >MCdE eF Save setup -Enable >MCeF dF -Disable >MCdF a Var Add -Set

MAE1E2E3 ( )

b -Read >MC

( ) A NO

( ) A NO ( ) A NO ( ) A NO

( ) A NO

( ) A NO ( ) A NO

>MCaMCMD

AMCMDMA E1E2E3 ( )

b ( ) AMCMDMA

E1E2E3 ( )

Serial I/O N Local Port Baud Rate >MCNh O Host to Slave Msg. P Msg for Host -No

123 >MCO (Msg) () A NO

1 >MCP ( ) A NO

-Yes >MC PP -Partial >MC PA -Control Codes >MC

( ) A NO

P ( ) A (Msg) ( ) NO PP ( ) A (Msg) ( ) NO PA ( ) A (Msg) ( ) NO

ANALOG INPUTS L Input value -Read >MA g Offsets -Calculate >MA W -Set >MAWc...k h -Calc and Set >MAhe X Gain (slope) -Calculate >MA Y -Set >MAYc...k Z -Calc and Set >MAZe N Range limits -Set >MANclm O -Read errors >MA Q -Clear Errors >MA P -Read and Clear >MA a Min Values -Read >MA b -Clear >MA c -Read and Clear >MA

Le ( ) A.....k( ) YES

g ( ) A.....k( ) YES

( ) A YES

( ) A.....k( ) YES

Xe ( ) A.....k( ) YES

( ) A YES

( ) A.....k( ) YES

( ) A YES O ( ) Acd( ) YES Qe ( ) A YES Pe ( ) Acd( ) YES

ae ( ) A.....k( ) YES

be ( ) A YES

ce ( ) A.....k( ) YES

C-2

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Appendix C

d Max Values -Read >MA e -Clear >MA f -Read and Clear >MA T Averages -Start >MA I -Complete? >MA U -Read >MA o -Read Linear °C >MA k Set temp sensor Type >MAkcx

Temp -Read Linear °C

de ( ) A.....k( ) YES

ee( ) A YES

fe( ) A.....k( ) YES

Tcj( ) A YES i( ) Ac( ) YES

Ue( ) A.....k( ) YES

oe( ) A.....k( ) YES

( ) A YES

A.....k

>MA

le( )

( ) YES

ANALOG OUTPUTS

J Level Value -set all same >MA K -Read >MA S -Set Selected >MA V Waveforms -Squarewave >MA

(Improved)-Triangle -Up >MA

-Dn >MA

-Sawtooth -Up >MA

-Dn >MA

-Ramp -Up >MA

-Dn >MA

-Terminate >MA

Jcl( ) A YES

Ke( ) A....l ( ) YES

Sc....l ( ) A YES

Vc4pqs( ) A YES Vc1pqs( ) A YES Vc5pqs( ) A YES vc3pqr( ) A YES vc7pqr( ) A YES vc2pqr( ) A YES vc6pqr( ) A YES vc0( ) A YES

DIGITAL INPUTS

M Read all modules >DD eH De-bounce -enable >DDeHen dH De-bounce -disable >DDdHe

M ( ) Ac ( ) Yes

( ) A No

Pulse Duration Measurements a Trig edges -set All b -set Pos c-set Neg d -Complete? >DD e Duration Ctr -Read g -Clear >DD

f -Read and Clear eG Pulse accum -Enable >DDeGe dG -Disable >DDdGe

y Pulse accum -Enable >DDye z -Disable >DDze

4 5 >DDae ( ) A Yes

4 5 >DDbe ( ) A Yes 4 5 >DDce ( ) A Yes

d ( ) Ac ( ) Yes

5 >DDee ( ) A....n ( ) Yes

ge ( ) A Yes

5 >DDfe ( ) A....n ( ) Yes

( ) A No ( ) A No

( ) A No

Pulse Counting

W Counters -Read >DD

Y -Clear >DD X -Read and Clear >DD U-Start>DD V-Stop>DD

T -Start/ Stop >DD el Freq Counter -Enable >DD dl Freq Counter -Disable >DD

We ( ) A....n ( ) Yes

Ye ( ) A Yes

Xe ( ) A....n ( ) Yes

Ue ( ) A Yes Ve ( ) A Yes Te ( ) A Yes

elen ( ) A No

dle ( ) A No

C-3

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Appendix C

Edge Detection N Edge latch -Set all >DDNe O -Set Off-to-On >DDOe

P -Set On-to-Off >DDPe

Q -Read >DD

S -Clear >DD R -Read and Clear >DD

( ) A Yes ( ) A Yes

( ) A Yes

Q ( ) Ac ( ) Yes Se ( ) A Yes Re ( ) Ac ( ) Yes

Event Logging

wA -Set/ Reset >DDwAe

wB -Read Buffer >DD wC -Clear >DD

( ) A ( ) No

wBe ( ) Av....w ( ) No

wCe ( ) A ( ) No

DIGITAL OUTPUTS

J Outputs On/ Off All Mod >DD

K Outputs -On >DD

L Outputs -Off >DD

Je ( ) A Yes Ke ( ) A Yes Le ( ) A Yes

Z Waveforms

One shot -On

-Off Delayed -On

-Off

Squarewave Fast Squarewave 8-Bit Fast Squarewave 16-bit Terminate >DD

h Re-trigger time delay >DD

I Pulses, 50% duty cycle

k Start Pulse - On

5 6 >DDZeHn ( ) A Yes

5 >DDZeJn ( ) A Yes

5 6 >DDZeln ( ) A Yes

5 >DDZeKn ( ) A Yes

5 >DDZeLtu ( ) A Yes

5 >DDZeMtu ( ) A Yes

5 >DDZeNtu ( ) A No

ZeG ( ) A Yes

he ( ) A Yes

5 >DDictn ( ) A Yes

5 >DDkcn ( ) A Yes

R -Off 5 >DD Rcn ( ) 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 guide see the duTec protocol manual.

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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 * MD Master unit digital I/O functions Factory setting 40Hex * MA Master unit analog I/O functions Factory setting 80Hex *

E1 1 E2 2 E3 3

Some instructions have counterparts in more than one unit:

DD --This instruction exists for MD, E1, E2, E3

IO --This instruction exists for MD, MA, E1, E2, E3 AU --This instruction exists for MC, MD, MA, E1, E2, E3 LU --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 four numbers is converted into a hex digit.

digital expander functions Factory setting C0Hex *

Digital expander functions Factory setting D0Hex *

digital expander functions Factory setting E0Hex *

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.

For e leading hex zeroes can be omitted.

Module#: 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0

Char- -2nd Char- -3rd Char- -4thChar-

-1

Bit pattern 0000 0001 0010 0011 0100 0101 0110 0111 Hex Digit:0 123456 7

Bit Pattern: 1000 1001 1010 1011 1100 1101 1110 1111

Hex Digit: 8 9 10 11 12 13 14 15

In all position fields, 1's specify which positions are affected and 0's are disregarded unless

they are listed below. c,d,e In instructions, 1's specify which positions are affectedfor 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 IO, 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 orfor setup G, which modules are configured as inputs for setup H, I which modules are not to be configured

C-5

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for setup m, digital, which outputs are to be set OFF for digital a, which input durations trigger on negative edges for digital J, which modules are to be OFF for digital N, which outputs latch from Off-to-ON for digital eG, dG, which inputs have pulse-accum. enabled/ disabled for 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 for digital d, analog I, which positions are complete for digital M, which modules are ON for digital Q, R, which positions have been triggered for c of analog O,P, which positions are over limits for 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 2 3

Appendix C

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 (14 if >655.35, watchdog multiplier (setup eD) instruction must be used.; then divide desired

period by 2.56 Sec. convert to hex (14

h Baud Rate local RS-232 Port (setup N) and network baud rate (setup c)

Desired

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 >1; multiply by module range for value, no input if ????. for analog g,h - convert each k to decimal, subtract 4095; if>8 subtract 16; multiply by

module range for offset. for analog o,

???? 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.

l,m

300 600 1200 2400 4800 9600 19,200 38,400

l Convert each k to decimal, divide by 16 for °C; if >2048 °C subtract 4096. If

** 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.

H to FFFFH)

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Appendix C

Range 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 l; for analog N high limit is l; low limit is m for analog K Convert each l 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 eI -divide desired timebase period (in seconds) by (0.01*TRM)convert to 2 hex

digits (0Ah=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 digits.

t squarewave On period (Digital I, 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-7

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Appendix C

x Temperature sensor type (analog k)

--------Thermocouples--------- RTD -Sensor-

Sensor E J J-1 K K-1 R S T T-1 T-2 100 100-1 590 set x to: 08

H 04H 14H 05H 15H 06H 07H 08H 18H 28H 03H 13H 01H

y Timer resolution multiplier, TRM (Setup a)

The basic 0.01second resolution of ALL of setup n; default value is 1

H; range is from 1H to FFH (1-255)

instructions noted with 5 are multiplied by y

z response codes from Setup F identify station type.

z=:00 010203

Type=: DD (Digital) MA (Analog) MC (Setup) --

Firmware version number x, yy, z

S 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 the 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.

C-8

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Appendix C

Special Responses:

A special response negates transmitted instruction.

N00 Power has been OFF N01 Invalid command N02 Checksum error N02 Checksum error *( Correct checksum)* if setup eC enabled N03 Instruction contains >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 N10 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, E1, E2, and E3 are

automatically set as shown below:

H MC Master unit control functions (display U0=MC)

H MD Master unit digital I/O function (display U1=MD)

H MA Master unit analog I/O function (display U2=MA)

H E1 1

H E2 2

H E3 3

in the variable mode individual addresses are independent and can range from 00

(0-255)

expander digital I/O functions (display U3=E1)

expander digital I/O functions (display U4=E2)

expander digital I/O functions (display U5=E3)

H to FFH

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 M C H

HHH PP,

the 2 digits after U0 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

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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= MFH

HHHLLPP

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

On application of power, the IOP flashes Go Go Go=

8, when the = appears, places the unit in setup mode RS-232 Device display shows:

device

(U0MC, U1MD, U2MA, U3ED, U4MF, H

- Offset and Variable modes

Entering Ctrl C from an RS-232

HHH,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 l for the number (1) an upper case character for a lower case one

C-10

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Notes:

Appendix C

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Index

2 Pass .................................................................3 - 3

4 Pass .................................................................3 - 3

Addressing ............................................................. C-5

Analog Inputs ............................................... 1 - 4, 1 - 9, 2 - 15

Analog Outputs .............................................. 1 - 4, 1 - 9, 2 - 17

Baudrate ...............................................................3 - 3

Cabling costs ...........................................................1 - 1

Chassis Setup ...........................................................2 - 1

CHECKSUMS .......................................................... C-8

Communications ........................................................1 - 7

Communications watchdogs ............................................... 1 - 6

Digital Expander ............................................. 1 - 1, 2 - 2, 2 - 14

Digital Inputs ...........................................................1 - 5

Digital Outputs ................................................... 1 - 9, 2 - 19

Environment ...........................................................1 - 8

Equivalent Circuit ....................................................... A-1

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

Frequency .............................................................1 - 9

Hardware watchdog ......................................................1 - 2

I/O Performance......................................................... A-1

IOP-AD ...............................................................1 - 8

IOP-D................................................................. 1 - 8

IOP-DE ............................................................... 1 - 8

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

JP3 ...................................................................2 - 9

JP5 ...................................................................2 - 9

Local control functions ...................................................1 - 6

Local RS-232 ..................................................... 1 - 7, 2 - 9

MAGIC ...............................................................3 - 8

Modem ...................................................... 1 - 7, 2 - 3, 2 - 9

Modem Jumpers.........................................................3 - 3

Modules ...............................................................1 - 9

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

Network type switch .....................................................3 - 3

OPTO-22/ OPTOMUX...................................................1 - 3

Pac ...................................................................1 - 8

Power supply ...........................................................1 - 9

Power Wiring...........................................................2 - 1

Protocol ............................................................... C-1

Pushbutton .............................................................3 - 4

Recv. LED .............................................................3 - 6

RS-232 ................................................................1 - 7

RS-422 ..................................................... 1 - 7, 2 - 3, 2 - 12

RS-485 ...............................................................2 - 11

RS-485 ..............................................................2 - 13

RT ................................................................... 1 - 9

RTD .................................................................2 - 15

RTS/CTS ..............................................................2 - 9

Sequential display .......................................................3 - 1

Setup .................................................................3 - 4

Setup pushbutton ........................................................3 - 1

Signal conditioning ......................................................1 - 2

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Index

Switches ........................................................2 - 12, 2 - 13

Thermocouple ................................................... 1 - 9, 2 - 15

Trans LED .............................................................3 - 7

Troubleshooting: ........................................................3 - 6

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Dutec I/O Plexer Hardware User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual