Nematron OptiLogic User Manual

OptiLogic Series

Opti

Logic

Optimal Automation for Industry

Input/Output Modules

Optimation, Inc.

[phone] 1

www.optimate.com

OptiLogic Series

WARNING

Thank you for purchasing industrial control products from Optimation, Inc. We want your new
system to operate safely. Anyone who installs or uses this equipment should read this manual
(and any other relevant publication) before installing or operating the system.

To minimize the risk of potential safety problems, you should follow all applicable local and
national codes that regulate the installation and operation of your system. These include the
National Fire Code, National Electric Code, and other codes of the National Electrical
Manufacturer’s Association (NEMA). There may be local regulatory or governmental offices
that can help determine which codes and standards apply to your situation. It is your
responsibility to determine which codes and should be followed, and to verify that the
equipment, installation, and operation is in compliance with the latest revision of these codes. If
you have any questions concerning the installation and operation of Optimation products, please
call us at [phone].

All Optimation products are warranted against defects in materials and workmanship for a period
of one year from the date of shipment. Warranty applies to unmodified product under normal
and proper use and service. Optimation’s sole obligation under this warranty shall be limited to
either, at Optimation’s option, repairing or replacing defective product. The cost of freight to
and from Optimation will be borne by the customer. No other warranty is given or implied.

This publication is based on information that was available at the time it was printed. We
constantly strive to improve our products and services, so we reserve the right to make changes
to the products and/or publications at any time without notice and without any obligation. This
publication may also discuss features that may not be available in certain revisions of the
product.

Trademarks

This publication may contain references to products produced and/or offered by other
companies. These products and company names may be trademarked and are the sole property
of the respective owners. Optimation disclaims any proprietary interest in the marks and names
of others.

Copyright 1999, Optimation, Inc.

All rights reserved

No part of this document shall be copied, reproduced or transmitted in any way without the prior,
written consent of Optimation, Inc. Optimation retains the exclusive rights to all information
included in this document.

Optimation, Inc.

[phone]

www.optimate.com

2

OptiLogic Series

Table of Contents

Introduction . . . . . . . . 6

Digital Inputs . . . . . . . . 7

Input Isolation . . . . . . . 7

DC Inputs . . . . . . . . 7

AC Inputs . . . . . . . . 8

Digital Input Voltage . . . . . . 8

I/O “Common” Terminals . . . . . 8

Digital Outputs . . . . . . . 9

Relay Outputs . . . . . . . 9

Transistor Outputs . . . . . . . 10

NPN Transistor Sinking Outputs . . . . 10

Solid State Relay Outputs . . . . . . 10

Analog Inputs . . . . . . . . 11

Isolation . . . . . . . . 11

Resolution . . . . . . . . 12

Accuracy . . . . . . . . 12

Range . . . . . . . . . 12

Multiplexing . . . . . . . . 12

Single Ended Inputs . . . . . . 13

Differential Inputs . . . . . . . 13

OL2104 Isolated Relay Output Module . . . 14

OL2108 Relay Output Module . . . . . 15

OL2109 DC Sinking Output Module . . . 16
OL2111 AC Solid State Relay Module . . . 17
OL2201 Digital Input Simulator Module . . . 18
OL2205 Isolated AC/DC Input Module . . . 19

OL2208 DC Digital Input Module . . . . 20

OL2211 AC Digital Input Module . . . . 21

OL2252 Dual High Speed Pulse Counter . . . 22

OL2258 High Speed Pulse Counter . . . . 25

OL2304 4 Channel Analog Voltage Output . . 28
OL2408 Analog Voltage Input Module . . . 29
OL2418 Analog Current Input Module . . . 30

Optimation, Inc.

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OptiLogic Series

OL2602 Dual RS232 Module . . . . . 31

Optimation, Inc.

[phone]

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4

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R

evision History

Issue

Date

Pages

Description

Original 8/99

1.1

1.2

1.3

1.4

1.5

Optimation, Inc. [phone] 5

1-24
1/00
9/00
04/01
09/02

13, 18, 25

25-28

various

15
10/2012 14, 15

Original release
Added OL2104, OL2205, OL2418
Added OL2258, OL2304
Added specs requested by UL
Changed wording of OL2108 voltage rating spec
Changed voltage ratings of OL2104 and OL2108

to match UL ratings

OptiLogic Series

OptiLogic Input/Output Modules

Introduction

Optimation’s OptiLogic series is a
flexible, modular system, designed to allow you
the ability to configure an optimal solution for
your exact needs. To accomplish this goal,
Optimation has developed a series of I/O
modules, communications modules, specialty
modules and operator panels that can be plugged
together in nearly any combination. This
manual covers the currently available modules
that plug into the card cage.

Additional I/O modules are under
development. Please check our web site at
optimate.com for a complete list of available
modules.

Most OptiLogic modules can be installed
in any card cage slot and used in any
combination and quantity that will fit in the card
cage. This applies to all general purpose digital
and analog I/O. If you need all digital inputs ­plug in digital input modules only. If you need a
mixture of analog and digital inputs and output ­select the mixture that fits your needs. Snap
together modularity gives you the ability to
optimize your system for your needs.

OptiLogic I/O modules are designed to
meet your needs in real world application. They
are all small circuit boards with a few available
points to minimize your system cost. Most
module connectors are pluggable terminal strips
for easy connection, and easy maintainability.
The snap-together design means low labor costs

- or costs on your time. Visual status indicators
on digital I/O and communications modules
provide a convenient means for monitoring
operation. All together, the result is a cost
effective, easy to use and maintain set of
industrial control hardware.

This manual covers general I/O
characteristics and applications first. Specific
I/O boards are covered in the latter pages. The
general pages should serve as a guide to
selecting and installing I/O boards in your
application.

Communications and specialty modules
are covered in the latter pages of this manual.

It is Optimation’s desire for this manual
to serve as a guide in your selection of the
modules appropriate for your application, as
well as to provide complete information for their
use.

Optimation, Inc.

[phone]

www.optimate.com

6

OptiLogic Series

processor

Sourcing DC input

Digital Inputs

Digital I/O modules are used to either
monitor (input) or control (output) the “state” of
something. “State” being on or off, active or
inactive, open or closed - etc. In the “real world”
digital I/O requirements come in a variety of
shapes and sizes. Therefore, there are a variety
of available modules designed to meet the
variety of needs.

Typical digital inputs are connected to
switches, buttons, digital outputs from other
equipment, discrete level sensors, thermostats
and other on/off sensing devices.

Digital status is sensed by a controller,
such as an OptiLogic system, by passing current
through an input sensor. When the current is on,
the input state is active. When it is not there, the
input state is inactive.

Input Isolation

In most cases, it is important to “isolate”
the real world inputs from the internal
electronics of the controller. You want to
prevent some external situation from “zapping”
the controller’s electronics.

figure shown, when the digital input contact
closes, the circuit path is complete and current
will flow. On the input module this circuit path
passes through a device which emits light when
current flows through it. The light emitter is in
very close physical proximity to (actually in the
same chip) a photo sensor, which will turn on
when it senses light. In this way, a digital input
module can sense whether the input device is
closed (current flow) or open (no current flow)
without a direct electrical connection between
the external sensor and the internal electronics.

DC Inputs

DC digital inputs are typically supplied
by a DC power supply. The most common DC
supplies used in industry are 12VDC and
24VDC.

Typical DC digital input circuits are
shown below. As shown, the physical optical
emitter on the input module is an LED (light
emitting diode). OptiLogic DC inputs use
bidirectional LEDs - i.e. Your inputs may either
source or sink current. The top figure shows a
sourcing input. The figure below it shows a
sinking input. When inputs are connected to a

“common” (most instances), inputs must be

either all sourcing or all sinking.

electrical isolation is optical isolation. The
figure below illustrates the basic concepts of
optical isolation of a digital input circuit. In the

Power
source

Optimation, Inc.

An effective means of providing such

sensor

optical
isolation

To

OptiLogic

Input module

[phone] 7

www.optimate.com

sensor

common

Sinking DC input

common

optical
isolation

OptiLogic
processor

Input module

optical
isolation

OptiLogic
processor

Input module

To

To

OptiLogic Series

Sourcing

10-30VDC

processor

AC Inputs

AC digital inputs are typically supplied
either directly from line voltage or transformed
down from line voltage. The most common AC
inputs are 120VAC and 24VAC, although any
voltage range is possible.

A typical AC input circuit is shown
below. As shown, the physical optical emitter
on the input module consists of two LEDs of
opposite polarity. An AC (alternating current)
connection flows current one way, then the
other. Light is emitted in both cases.

sensor

optical
isolation

To

OptiLogic

maximum voltage corresponds to the maximum
current the optocoupler can handle without
being damaged.

I/O “Common” Terminals

For a digital input circuit, one input
terminal and one output terminal is necessary for
operation. For practical application, one of these
two terminals may be “common” to several
circuits.

In most systems, the power source for all
digital inputs is from the same supply. In such
cases, connecting all of the circuit return lines
together results in reduced equipment costs as
well as simpler system wiring.

The example below illustrates a digital
input board that has eight inputs and two
commons. This can be accomplished with a 10
terminal connector block.

Input module

There is a short period when voltage, and
therefore current flow, switches from one
direction to the other when no current flows.
This is called zero crossover. During zero
crossover, the digital input circuit must

“debounce” the signal to ensure that the system

does not provide a false indication that the input
contact is not closed when it is, in fact, closed.
OptiLogic AC digital inputs handle such zero
crossover conditions.

Digital Input Voltage

Any digital input module, AC or DC, is
designed to operate within an input voltage
range. The input voltage directly controls the
amount of current flowing through the circuit.
The minimum voltage corresponds to a voltage
that creates enough current to produce LED light
sufficient to be sensed by the optical sensor. The

IN7

IN6

IN5

IN4

IN3

IN2

IN1

IN0

10-30VDC

Sinking

IN7

IN6

IN5

IN4

IN3

IN2

IN1

IN0

10

9

8

7

6

5

4

3

2

1

10

9

8

7

6

5

4

3

2

1

Optimation, Inc.

[phone]

www.optimate.com

8

OptiLogic Series

Digital Outputs

Digital outputs are used to turn “loads”
on and off. “Loads” may be lights, motors,
solenoids, or any type of on/off device found in
the “real world”.

Digital outputs in the OptiLogic series
come in three types - relay, transistor and solid
state relay. Each type has applications it is best
suited for. The following is a general list of
application characteristics for each output type.

Relay

•

Low contact loss

•

AC or DC

•

Moderate to high current rating

•

Low cost

Should not be used for

•

Ultra low current switching (less than 10mA)

•

Switching loads at high frequency

Transistor

•

DC application only

•

Low current rating
High frequency switching

•

•

Low cost

Relay Loads

Relays are affected by the type of load
that is switched. Inductive loads (solenoids,
motors, etc.) tend to wear the relay much more
than resistive loads (lights, heaters, etc.).

Inductive load wear is due to the fact that
inductive loads will continue to conduct current
for a period, even after the circuit is broken. This
current flow builds up opposing polarity charges
between the contact segments that just
separated. This makes the two segments attract
each other - making opening the contact more
difficult. It also can result in arcing while the
contact is being opened. Arcing, in turn, builds
up carbon deposits, i.e. wear.

This situation can be improved for DC
inductive circuit loads by the addition of
external diode protection of the circuit. The
figure below illustrates diode protection. When
the contact is closed, the diode is reverse biased
and no current flows through it. When the
contact opens, current will continue to flow
through the inductive load. The diode provides a
path for current flow. The result that is the
energy is dissipated in the inductive coil and not
the relay contact.

Inductive load

Solid State Relay

•

AC application

•

Any switching frequency

•

Moderate current

•

Moderate cost

Relay Outputs

Relays are basically electrically
controlled mechanical switches. All current
OptiLogic Relay output boards utilize form A
relays - i.e. the contact is either open or closed.

Optimation, Inc.

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Diode protection

isolation

From
OptiLogic
processor

Output module

Note : Do not use this circuit for AC loads.

OptiLogic Series

processor

processor

Transistor Outputs
NPN Transistor Sinking Outputs

An NPN transistor sinking output
provides a path to ground. A typical circuit is
shown below.

Inductive load

optical

Diode protection

There is a small voltage drop across the
transistor in such a circuit. The voltage drop will
generate heat in the transistor. Therefore NPN
transistor outputs are generally limited to lower
current applications.

isolation

From

OptiLogic

Output module

Solid State Relay Outputs

Solid state relays are semiconductor
switches that operate very much like mechanical
relays. They have an advantage over mechanical
relays by virtue of the fact that they are
semiconductors. Solid state relays can be
switched at relatively high frequencies and they
do not wear out. However they are more
expensive and there is a small voltage drop
across the contact.

The figure below illustrates a typical
solid state relay output. OptiLogic Solid state
relays are designed for AC load operation.

load

optical
isolation

From

OptiLogic

Transistor outputs can be operated at
high frequency. There is no effective wear on a
transistor output from switching, as there is in a
mechanical relay.

Diode protection applied to inductive
loads is recommended in cases where the load
current approaches the rated current limit of the
output. In most cases OptiLogic outputs are
designed to withstand voltages of at least twice
the rated output voltage. However, diode
protection like that shown above will ensure that
turn off voltage spikes will never get to that
level.

Output module

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[phone]

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10